Air compressor maintenance cost reduction methods and measures

According to the law of market competition, what exists is reasonable, and what is unreasonable will be gradually eliminated by the market. Therefore, a large number of air compressor maintenance costs on the market remain high for a long time, and there are rational and objective reasons for its existence, which requires practical analysis combined with industry development and equipment procurement management concepts.

Nowadays, the independent and closed maintenance system within enterprises formed in the past 30 years of reform and opening up is facing a severe impact, and the more open, flexible and resource-optimized social maintenance cooperation ecology (flexible maintenance support service system) is advancing from south to north from east to west, which is also in line with the law of market competition.

Unfortunately, China's experts, scholars, and industry elites have long focused on the thinking and research of the internal equipment management system model and maintenance methods. How to share, optimize and share limited and underutilized maintenance resources (including maintenance personnel, maintenance technology and advanced maintenance equipment and tools) in a wider range and at a wider level with the Internet thinking mode

Winning is not given enough attention.

In the "Internet +" era, it is possible to achieve social cooperation problems that cannot be solved by a single enterprise by building an "Internet + air compressor maintenance ecology" system.

1, strengthen equipment update and technical transformation

With the rapid development of modern science and technology, the application of air compressor equipment renewal and new technology has a very obvious effect on improving the operational reliability of equipment and reducing maintenance costs. At present, the air compressor equipment of many enterprises is still more than ten years ago, and the technology is backward, the production efficiency is low, the operation is bulky, and the spare parts are expensive. Some of this old equipment needs to be eliminated, and some can be technical transformation, which will greatly reduce the cost of maintenance and spare parts.

2, good spare parts quality control

The quality of spare parts directly determines the service life of the machine, the reliability of the equipment and the scope of maintenance. Good quality spare parts can not only help maintenance personnel solve the fault in time, but also improve the reliability of the entire system, extend the service life of related components, and improve the overall performance of the equipment. On the contrary, poor quality spare parts can not only solve the problems in the equipment, but also cause new failures, reduce the reliability of the system, and even cause disaster. For example, we often use the filter element, lubricating oil, if the quality is not good, it will cause blockage, overheating, wear and other failures, not only the service life is short, but also cause the equipment should not stop when the stop, easy to occur production accidents.

3, strengthen the management of replacement parts in maintenance

In the troubleshooting of air compressor, especially when the user performs maintenance by himself, such a situation often occurs that the spare part is broken but the spare part is replaced, or the equipment needs to be adjusted but the spare part is replaced, resulting in waste. The reason for this phenomenon is that spare parts management lacks corresponding supervision mechanism, and maintenance workers are not responsible for the quality of replaced spare parts. This requires the establishment of a mechanism, so that each maintenance worker is responsible for their own replacement parts, to ensure that the replacement parts are really damaged. The replacement of spare parts shall be reviewed by the identification team composed of relevant personnel, and the replacement of spare parts found to be not damaged shall be punished. The identification team is responsible for the identification results, and those who intentionally misidentify for personal gain will be strictly punished, so that the problem of easy replacement of spare parts can be solved.

There is also a problem in actual operation, that is, maintenance personnel can not judge the extent of damage to spare parts. For the parts suspected to be faulty during maintenance, the maintenance worker can eliminate them by replacement method. If the part is normal, it must be reloaded and new spare parts are not allowed to be used. The replacement spare parts should be accurately recorded, the supervision of spare parts should be strengthened, the use records should be made, and the average service life should be calculated, so as to reduce the inventory of spare parts, and timely purchase of spare parts before they are damaged to prevent spare parts from being insufficient.

4. Responsibility of maintenance personnel

With the extension of the service life of air compressors, the aging of equipment is an irreversible fact. The replacement of aging spare parts may be carried out at any time, and the replacement of spare parts is largely in the hands of maintenance workers, and there are many factors of "human mastery" replacement. Maintenance personnel need to know the usage of spare parts, estimate the damage time of spare parts, and prepare spare parts for timely replacement

In this way, it can reduce the equipment maintenance time, avoid the waste of spare parts, and reduce the warehouse inventory. This requires maintenance workers to have a sense of ownership and a strong sense of responsibility, business leaders must first of all pay attention to maintenance workers, so that maintenance workers feel sorry for the enterprise if they do not do it carefully.

5. Strengthen the maintenance of available spare parts

Many of the damaged spare parts replaced can be reused after repair, but many maintenance workers are reluctant to repair damaged spare parts, roughly for the following reasons:

(1) Lack of necessary maintenance tools. The original maintenance concept believes that the mechanical maintenance worker only needs a hammer, screwdriver and a wrench, while the electrical maintenance worker's tool is a multimeter, a needle nose pliers, a screwdriver, a roll of insulation tape, such a simple tool is impossible to repair the damaged spare parts. Therefore, enterprises need to be equipped with the necessary maintenance tools.

(2) Lack of corresponding incentive mechanism. The original management concept believed that the use of waste parts during the working time of maintenance workers was within the scope of work, and failure to repair was derelelism. Maintenance workers worked hard to repair a higher-priced spare part, paid a lot of energy and labor, but did not get any encouragement or reward, and the labor they paid was simply disproportionate to the income. Therefore, the enthusiasm for the reuse of waste parts is lost. Enterprises should take corresponding incentive measures, depending on the price of spare parts, reuse value, reliability, etc., with a certain percentage of the price of spare parts to reward the repair of spare parts personnel, and linked to the evaluation, in order to stimulate the enthusiasm of maintenance personnel for the reuse of waste parts.

6. Strengthen the management of spare parts

Some types of spare parts in the spare parts warehouse are insufficient, and some types are overstocked. It is necessary to set up an upper and lower limit ledger for common spare parts to ensure that the upper limit is not lower than the lower limit. In this way, the normal operation of the equipment can be ensured and the spare parts cannot be overstocked.

7, extend the service life of components

Encourage technical research to extend the service life of vulnerable components. Many vulnerable components can extend their service life through technical improvement, which can also save a lot of maintenance costs.

Many times, air compressor manufacturers have tested tens of thousands of hours of products, and they have just broken down before they reach the user's hands. Users complain about poor product quality - which is actually often caused by unreasonable use by user operators.

Many operators claim to understand technology, often for the new air compressor equipment lazy to learn the operation manual and regulations, that are screw compressors, the difference is not big. In fact, air compressors have different requirements for operation and maintenance time and techniques because of their different designs, different specifications and different working conditions. Specious, not paying attention to details is often the root of failure.

8, adhere to the day week month maintenance system

Formulate a strict maintenance system, prompting the operator to do it in strict accordance with the regulations, find the hidden trouble and deal with it in time, eliminate the fault in the bud, in order to extend the service life of spare parts. This is especially important for support lubrication components and electrical components.

In short, reducing the maintenance costs of air compressors can not be solved through one or two aspects of efforts, and the problem must be solved thoroughly through the effective combination of all aspects, and the need to persevere in order to achieve good results.