Zero fault means allmachineIt is carried out in accordance with the requirements at all times.
fault type
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Among the seven major losses of equipment, the most important factor affecting efficiency isfaultLosses.The definition in JIS is "failure means that the equipment has lost the specified function".The failure can be divided into two types according to the form of loss of function.
As far as the definition of "failure means that the equipment has lost the specified function" is concerned, failures can be divided into two categories from the perspective of the form of loss of function.
1. Function stop type fault.
It is generally called "sudden failure".
2. Function decline type fault.
Although the equipment is in operation, it often produces waste products, inspection shutdowns, speed drops and other losses, which can not give full play to the function of the equipment. It refers to the situation of partial defects.For example, fluorescent lamps are often dark and bright.
Deterioration form
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1. The service life of forced deterioration is shorter than that of natural deterioration
Deterioration is divided into natural deterioration and forced deterioration.The so-called natural deterioration means that although the method of use is correct, the equipment has undergone physical changes over time, and the initial performance begins to decline.For example, although the specified parts are filled with oil according to the appropriate amount and period, the physical performance of the equipment will still gradually deteriorate.
The so-called forced deterioration means that the operation is not carried out according to the proper method, which artificially promotes the deterioration.For example, no oil is added at the place where the oil should be added, or the amount of oil added is too small or the cycle is too long although the oil is added.There are also parts that have not been cleaned. Failure to do what should be done will lead to equipment deterioration.In this way, the service life of the equipment is less than its due life, which is much shorter than the life of natural deterioration.
2. Whether there is forced deterioration in our factory
Whether there is forced deterioration in the factory. A loose bolt will cause vibration in one part. The vibration will gradually become serious, which will cause vibration in other parts. This phenomenon is common in daily work.Take the limit switch as an example. If the lubricating oil quality is poor, the contact part at the stop of the limit switch will deteriorate, which is forced deterioration.
3. Recovery
Restoration is to restore to the original correct state.All equipment will age with the passage of time. Determine its aging degree. If it is above a certain limit, it should be restored to the original normal state.How to measure the aging, what is the limit, and how to set the original normal state of the equipment.These are necessary prerequisites.When it is necessary to restore, the balance of strength and accuracy of the whole equipment shall be considered.If only the fault and specific parts are recovered, the overall balance cannot be achieved, so pay attention to the relevant parts of the fault.
Implementation method
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The starting point for zero failure
The equipment failure is caused by human.Therefore, everyone related to equipment should change their own ideas.It is necessary to change the viewpoint of "equipment always fails" to "equipment will not fail" and "failure can be reduced to zero", which is the starting point of zero failure.
Summarize the basic ideas of zero fault:
1. The equipment failure is caused by human.
2. After people's thinking and actions change, the equipment can achieve zero failure.
3. The concept of "equipment failure" should be changed to "equipment failure free" and "zero failure".
Expose the "potential defects" of the fault
First, analyze how the fault occurs.This is because we did not notice the seed defect of the fault before it was generated.
In this way, the seeds of failures that we did not pay attention to are called latent defects.According to the principle of zero failure, it is to make these "potential defects" obvious (pay attention to them before failure).In this way, the fault can be avoided by correcting (repairing) these defects before they form a fault (preventing them from happening - preventing them from happening).
Generally speaking, the so-called potential defects often refer to dust, dirt, wear, deflection, looseness, leakage, corrosion, deformation, scars, cracks, temperature, vibration, sound and other abnormalities.There are many defects, which people think will not be affected if they do not deal with them, or that these defects are relatively minor, which does not matter.
1. Potential defects in physics - physical defects that cannot be seen by the eyes, so more attention is paid to them.
(1) Internal defects that have not been analyzed, inspected or understood.
(2) The installation position is poor and invisible defects.
(3) Invisible defects such as dust and dirt.
2. Psychological potential defects - the awareness or skills of the security personnel or operators are insufficient, so the existing defects are found
Five countermeasures to achieve zero failure
1. Basic conditions are met.
The so-called basic conditions refer to cleaning, oiling, fastening, etc.The failure is caused by (equipment) deterioration, but most of the equipment deterioration does not have the basic conditions for deterioration.
2. The use conditions shall be strictly observed.
The use conditions of the equipment or machine are predetermined at the time of design.If the equipment and machines designed according to the service conditions are strictly met, they will rarely have failures.For example, the voltage, speed, installation conditions and temperature are all determined according to the characteristics of the machine.
3. Restore the equipment to normal.
Even if a piece of equipment strictly abides by the basic conditions and service conditions, it will deteriorate and cause faults.Therefore, it is necessary to make the deterioration of the hidden danger obvious and restore it to the normal state.This means that the inspection should be carried out correctly, and preventive repair should be carried out to restore the equipment to normal.
4. Improve the design shortcomings.
Some faults cannot be removed even after the above three countermeasures are taken.And sometimes these failures increase production costs.This kind of equipment is mostly in the design or production construction stage, resulting in insufficient technical force or errors and other shortcomings.Therefore, the failure should be carefully analyzed to improve these shortcomings.
5. Improve skills.
The above 1-4 countermeasures are all implemented by people. The most problematic is that even if countermeasures 1-4 are adopted, operation errors and repair errors will occur.The only way to prevent such failures is to improve the professional skills of operators and security personnel.
The above five countermeasures to achieve zero failure must be coordinated by the operation department and the security department.That is, in the operation department, it is necessary to focus on the preparation of basic conditions, strict observance of use conditions, and improvement of skills.The implementation project of the preservation department has strict compliance with the use conditions, recovery of deterioration, countermeasures for shortcomings, and improvement of skills.
6. Three activities to prevent deterioration.
(1) Activities to prevent deterioration: correct operation, preparation, adjustment, cleaning, refueling, fastening, etc.
(2) Deterioration activities: check the service conditions, and conduct daily and regular inspection on the equipment to find the "root cause" of the fault as soon as possible.
(3) Recovery activities: strengthen the small servicing and the handling and liaison of abnormal conditions.To restore the equipment to normal state, prevent failure before it happens.
starting point
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The equipment failure is caused by human.Therefore, everyone related to equipment should change their own ideas.It is necessary to change the viewpoint of "equipment always fails" to "equipment will not fail" and "failure can be reduced to zero", which is the starting point of zero failure.
Summarize the basic ideas of zero fault:
1. The equipment failure is caused by human.
2. After people's thinking and actions change, the equipment can achieve zero failure.
3. The concept of "equipment failure" should be changed to "equipment failure free" and "zero failure".
2. Expose the "potential defects" of the fault
First, analyze how the fault occurs.This is because we did not notice the seed defect of the fault before it was generated.
In this way, the seeds of failures that we did not pay attention to are called latent defects.According to the principle of zero failure, it is to make these "potential defects" obvious (pay attention to them before failure).In this way, the fault can be avoided by correcting (repairing) these defects before they form a fault (preventing them from happening - preventing them from happening).
Generally speaking, the so-called potential defects often refer to dust, dirt, wear, deflection, looseness, leakage, corrosion, deformation, scars, cracks, temperature, vibration, sound and other abnormalities.There are many defects, which people think will not be affected if they do not deal with them, or that these defects are relatively minor, which does not matter.
(1) The potential defects of physics - physical defects that cannot be seen by the eyes, so they are paid more attention to.
(1) Internal defects that have not been analyzed, inspected or understood.
(2) The installation position is poor and invisible defects.
(3) Invisible defects such as dust and dirt.
(2) Psychological potential defect - the awareness or skills of the security personnel or operators are insufficient, so the existing defects are found.
countermeasure
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1. Basic conditions are met.
The so-called basic conditions refer to cleaning, oiling, fastening, etc.The failure is caused by (equipment) deterioration, but most of the equipment deterioration does not have the basic conditions for deterioration.
2. The service conditions shall be strictly observed.
The use conditions of the equipment or machine are predetermined at the time of design.If the equipment and machines designed according to the service conditions are strictly met, they will rarely have failures.For example, the voltage, speed, installation conditions and temperature are all determined according to the characteristics of the machine.
3. Restore the equipment to normal.
Even if a piece of equipment strictly abides by the basic conditions and service conditions, it will deteriorate and cause faults.Therefore, it is necessary to make the deterioration of the hidden danger obvious and restore it to the normal state.This means that the inspection should be carried out correctly, and preventive repair should be carried out to restore the equipment to normal.
4. Improve the design shortcomings.
Some faults cannot be removed even after the above three countermeasures are taken.And sometimes these failures increase production costs.This kind of equipment is mostly in the design or production construction stage, resulting in insufficient technical force or errors and other shortcomings.Therefore, the failure should be carefully analyzed to improve these shortcomings.
5. Improve skills.
All countermeasures should be implemented by people, and people are the most fundamental in the process of realizing zero failure.First of all, everyone should have a serious attitude and conscientious spirit. Second, they should have a correct understanding of failures. Finally, they should improve the professional skills of operators and maintenance personnel.
In general, we should do a good job in the following aspects in our daily work: activities to prevent deterioration: correct operation, preparation, adjustment, cleaning, refueling, fastening, etc;
The above 1-4 countermeasures are all implemented by people. The most problematic is that even if countermeasures 1-4 are adopted, operation errors and repair errors will occur.The only way to prevent such failures is to improve the professional skills of operators and security personnel.
The above five countermeasures to achieve zero failure must be coordinated by the operation department and the security department.That is, in the operation department, it is necessary to focus on the preparation of basic conditions, strict observance of use conditions, and improvement of skills.The implementation project of the preservation department has strict compliance with the use conditions, recovery of deterioration, countermeasures for shortcomings, and improvement of skills.
