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Organization of production - Kurochkin A.S.

Equipment repair planning

The planning of equipment repair is based on the ECMAS and the Model

Scheme of maintenance and repair (TSTOR), which, in turn, are based on the following basic standards:

• category of repair complexity;

• Repair unit;

• duration and structure of the repair cycle;

• the duration of overhauls and inspections.

Under the category of repair complexity is understood the degree of complexity of repair of the unit (a unit of equipment), which depends on its technical and design features - the dimensions of the machined parts, the accuracy of their manufacture, repair characteristics, etc. The category of repair complexity is denoted by the letter I and the number in front of it.

The category of repair complexity of equipment is determined both by mechanical and electrical parts. So, at present, for metalworking machines according to TSTOR, a 16K20 lathe-screw-cutting lathe has been adopted as the standard assembly. For him a category of complexity of 12 Y is established. For any other machine of this group, the complexity category is determined by comparing the selected machine with the standard.

The repair unit is a conditional indicator characterizing the standard costs of repairing equipment of the first category of complexity - r e. For repair unit complexity of the mechanical part, the repair complexity of the conventional equipment is accepted, the labor-intensive repair of which in the medium in terms of RMC equipment is 50 h, and for the unit of repair complexity of the electrical part of the equipment - 12.5 h. The complexity of equipment repair is determined by the number of repair complexity units Assigned to one or another group of equipment. Thus, the repair unit coincides with the category of complexity with respect to the numerical value and for the machine model 16K20 is equal to 12, ie, r e = 12 for the mechanical part and r e = 9 for the electric one.

The time norms for one repair unit are set by the types of repair work (Table 14). The length of the idle time of the equipment for repairs is also regulated by the standstill standards for one repair unit (Table 15).

The resulted specifications at each enterprise are subject to updating taking into account a character of work of the equipment, features of the enterprise, equipment of a repair economy, etc. They are a basis of calculation of the general annual volume of repair work and interrepair services (at first calculations for each group of the equipment separately, and then are summed up on groups , As a result, the overall complexity of repair work and maintenance for the planned year for the enterprise is obtained).

Table 14

NORMAL TIME FOR ONE REPAIR UNIT (for technological and lifting-transport equipment)

Table 15

NORMS OF DURATION OF EQUIPMENT DURING REPAIR ON ONE REPAIR UNIT, days

The repair cycle is the length of the equipment from the beginning of commissioning it to the first major overhaul or between two major repairs. According to the SSTOR, for each type of equipment of a certain technological purpose, the initial duration of the repair cycle is established, which at the enterprises can be adjusted based on the operating conditions of the equipment. For example, for machine tools, the length of the repair cycle is Tc = 16800 h, for the press-forging equipment Tc = 10000 h, for the woodworking Tc = 11200 h, for the foundry Tc = 6000 h. For metal cutting equipment, in calculating the length of the repair cycle, Enterprise. These factors in the form of coefficients are determined by reference tables of the TSTOR.

The structure of the repair cycle is understood as the number and sequence of performance of inspection and repair work between the commissioning of the equipment and the first major overhaul or between major repairs.

The unified system of PPR provides for a certain structure of repair cycles for equipment groups, taking into account the purpose, complexity and operating conditions. An example of the structure of the repair cycle is shown in Fig. 15 (while the repair cycle includes overhaul, two medium, six small and nine inspections).

The duration of the overhaul period (tmr) is determined as follows, h:

Where n, pm, by - the number of medium, small repairs and inspections, respectively, for one repair cycle.

Equipment repair is planned in a certain sequence. In the UGM of the enterprise, with the participation of the mechanics of all workshops, an annual schedule for the repair of all equipment is prepared. The calendar terms of repair are determined on the basis of entries in the logs of the operation of equipment. The annual repair schedule includes inspections and all types of repairs. For each unit of equipment, the repair schedule is developed on the basis of the type and duration of the last repair, the structure of the repair cycle, the duration of the overhaul period, the repair complexity groups and the labor-intensity standards. Plans-schedules are coordinated with heads of shops and are confirmed by the chief engineer.

Based on the approved schedules, annual repair work is calculated. It, as a rule, is calculated by types of repair in repair units and by standard labor input (Table 16).

Table 16

SCOPE OF REPAIR WORK ON ENTERPRISE FOR 2001 (conditional example)

Planning the work of the RMC

As noted, the main purpose of the RMC is to perform major repairs and manufacture spare parts for equipment repair. In addition, the RMC manufactures installation of moving and dismantling of old equipment, and also produces non-standard equipment.

The structure of the RMC (the most typical) includes the following technological areas: machine (mechanical), mechanic-assembly, tin, thermal and forging. In large RMC there is a site for the restoration of details by the method of metallization, surfacing, etc.

Planning of the RMC's work is conducted by methods appropriate to planning in mechanical workshops with a single and small-scale production. Based on the annual schedule of repairs, the department of the OCM establishes a quarterly plan for the shop with a breakdown by months in repair units and standard hours for such basic types of work: repair of equipment; Inspection, checking for accuracy; Washing; Manufacturing of spare parts and non-standard equipment; Other types of work. In addition, provision is made for up to 7-10% for unplanned (emergency) work.