PO 车间设备故障针对性维护计划

PO 车间设备针对性故障维护计划

一、主机

1. 不加热、加热不停、升温慢、漏电等。
   • 每周至少对加热圈固态继电器线路检查两次。坏的及时更换，漏电故障每天要对设备漏电至少一次以上检查。
2. 洗了机不吸料，供不上料。
   • 定期对车间进行培训。吸料机过滤网培训两天清理一次。发现坏的过滤网及时进行更换。
3. 电机风机的保养与检查。
   • 每周至少对设备进行一次以上对电机、风机的尘土除尘保养清理。
4. 其他主机零部件的检查，对主机零部件和色母机每周至少一次以上检查。

二、自动包装设备

1. 对车间人员自动包装机进行培训。对家电机构、光电开关、振动盘等易损配件进行两次以上检查每天。
2. 日常维护加油润滑，每周至少两次以上全方位的润滑保养。

三、打压机缠绕包装机

• 每周对打压机电磁阀至少两次以上检查。对车间人员进行培训，每周对缠绕包装机设备主轴检查不少于两次。对车间进行培训。

IM 分厂综合故障针对性解决计划

一、模具问题

1. 机台人员加强培训重视，减少无意识人为损坏。
2. 生产车间对各模具统一做出相应标注。例如，分 AA、A、AB、ABB 等级性修复，并有纸质问题说明和最后一模样品作为维修参考。
3. 加强对模具维修人员培训技能性自主和外在提升。
4. 对模具修复辅助设备进行采购。

二、注塑机

1. 对加热系统部分进行技改，正在维修中。
2. 碎片机问题主要是加强对操作人员管理，特别是不要一次性加入太多原料。
3. 其他机械故障主要是润滑不到位，加强设备维护保养，多巡查多计划。
4. 水、电、气铺设不合理，逐步进行改善。

三、自动包装机设备

1. 加强员工操作技能培训。全是女工，有先天劣势。
2. 电路电气配件要经常备齐。
3. 专人进行辅助性帮扶维修，解决疑难问题。

维护保养记录

1. PVC 维护保养一周三次，例如高混冷混上料料龙；周二周四周末保养。
2. 排水机台大型维护保养一月两次，小型保养一月四次。
3. 线管包装机维护保养滑块轨道轴承一礼拜两次，一个月至少八次。
4. 线管切割机自动供油一礼拜至少检查两次油壶油位。

机台加热故障整改计划

1. 一主机螺桶加热圈，在采购不锈钢接线丝母。
2. 一机桶加热线链接点，做好物料防氧化措施；例如高温布胶布缠绕，及加热温穿高温蜡管。
3. 一螺桶一二三区更换大功率接触器，例如 1810 更换 2510，这样效果更好，在一个就是采购品牌配件。
4. 一排水机台，定台，定机，少拆磨具加热系统故障会降到 96%。

Maintenance Plan for Targeted Equipment Faults in the PO Workshop:

I. Main Machine:

1. Heating failure, slow temperature rise, electrical leakage, etc.
   • Conduct at least two inspections of the heating coil and solid-state relay circuit per week. Replace any faulty components promptly. Check for electrical leakage at least once a day.
2. Failure to absorb material or supply material.
   • Provide regular training for workshop personnel. Clean the suction machine filter at least once every two days. Replace any faulty filters promptly.
3. Maintenance and inspection of motor and fan.
   • Clean and maintain the motor and fan at least once a week to remove dust.
4. Inspection of other main machine components and color masterbatch machine.
   • Conduct at least one inspection per week of the main machine components and color masterbatch machine.

II. Automatic packaging equipment:

1. Provide training for workshop personnel on the operation of automatic packaging machines. Inspect vulnerable parts such as home appliance mechanisms, photoelectric switches, and vibration plates at least twice daily.
2. Perform regular lubrication and maintenance at least twice a week.

III. Wrapping and packaging machine:

• Inspect the electromagnetic valve of the wrapping machine at least twice a week. Provide training for workshop personnel on the inspection of the packaging machine's spindle at least twice a week.

Comprehensive Troubleshooting and Targeted Solution Plan for IM Sub-Plant:

I. Mold Issues:

1. Strengthen training for machine operators to reduce unintentional damage.
2. Mark each mold with corresponding annotations and repair levels (e.g., AA, A, AB, ABB) in the production workshop. Provide paper instructions and keep the last mold sample as a reference for repairs.
3. Enhance the skills of mold repair personnel through training and external improvement.
4. Purchase auxiliary equipment for mold repair.

II. Injection Molding Machine:

1. Ongoing maintenance and improvement of the heating system.
2. Address issues with the crusher by improving operator management, particularly avoiding excessive addition of raw materials.
3. Address other mechanical failures by improving equipment maintenance and conducting regular inspections.
4. Gradually improve the layout of water, electricity, and gas pipelines.

III. Automatic packaging machine:

1. Strengthen training for employees in operating skills, particularly for female workers who may have inherent disadvantages.
2. Ensure a sufficient supply of electrical circuit components.
3. Provide dedicated personnel for assistance in troubleshooting and repairs.

Maintenance and Repair Records:

1. PVC maintenance and repair: Three times per week, such as for high-mix cold mixing and material feeding on Mondays, Wednesdays, and weekends.
2. Large-scale drainage machine maintenance: Twice a month; small-scale maintenance: Four times a month.
3. Line pipe packaging machine maintenance: Lubricate slide tracks and bearings twice a week, at least eight times a month.
4. Line pipe cutting machine automatic lubrication: Check oil level in oil cans at least twice a week.

Machine Heating Failure Rectification Plan:

1. Replace stainless steel wire connectors for heating coils on the main machine barrel.
2. Implement anti-oxidation measures for the connection points of the heating wires on the main machine barrel, such as using high-temperature adhesive tape or high-temperature wax tubes.
3. Replace high-power contactors (e.g., replace 1810 with 2510) for the heating zones of the main machine barrel. Procure branded components.
4. Minimize disassembly of molds and heating systems on the drainage machine to reduce the occurrence of faults.