Air compressor maintenance cost reduction methods and measures

According to the law of market competition, existing is reasonable, unreasonable will be gradually eliminated by the market. Therefore, a large number of maintenance costs of air compressors on the market remain high for a long time, and there must be rationality and objective reasons for their existence, which requires practical analysis based on the industry development and the concept of equipment procurement management.

Nowadays, the reform and opening up 30 years of enterprise internal independent closed service system is facing a severe shock, more open, flexible, and social resources optimization maintenance collaboration ecological maintenance support service system (flexible), are from the south to the north from the east side to the west, this also is accord with the laws of market competition.

Unfortunately, experts and scholars in our country, the industry elite, has long focused on enterprise equipment management system mode and maintenance mode of thinking and research, on how to put limited and low utilization rate of resources of high quality maintenance (including maintenance personnel, maintenance technology and advanced maintenance equipment installation tools, etc.) in a larger scope broader level by Internet way of thinking for sharing, optimization and win-win situation, did not give enough attention.

In the era of comprehensive "Internet +", the "Internet + air compressor maintenance ecology" system can be built to achieve social cooperation problems that cannot be solved by a single enterprise.

1. Strengthen equipment update and technical transformation

With the rapid development of modern science and technology, the update of air compressor equipment and the application of new technology can improve the operation reliability of equipment and reduce maintenance costs, which has a very obvious effect. At present, many enterprises air compressor equipment more than ten years ago, backward technology, low production efficiency, heavy operation, expensive spare parts. Some of these old equipment must be phased out, while others can be technically modified, which will greatly reduce the cost of maintenance and spare parts.

2. Quality control of spare parts

The quality of spare parts directly determines the service life, equipment reliability and maintenance range. High-quality spare parts can not only help maintenance personnel to solve the problems in time, but also improve the reliability of the whole system, extend the service life of relevant parts and improve the overall performance of the equipment. On the contrary, low-quality spare parts can not only fail to solve the problems in the equipment, but also cause new failures, reduce the reliability of the system and even lead to disaster. For example, if the filter element and lubricating oil we often use are of poor quality, it will lead to problems such as blockage, overheat and wear, which will not only have a short service life, but also make the equipment stop when it should not be stopped, resulting in production accidents easily.

3. Strengthen the management of spare parts to be replaced during maintenance

In the fault treatment of air compressor, especially when the user carries out the maintenance, such a situation often occurs, this spare part is broken but replaced, or the equipment needs to be adjusted but replaced spare part, 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 replacement of spare parts. This requires the establishment of a mechanism whereby each maintainer is responsible for the spare parts he has replaced to ensure that the replaced spare parts are indeed damaged. The replacement of spare parts shall be examined by the evaluation group composed of related personnel, and the replacement of spare parts without damage shall be punished by the replacement. The appraisal group is responsible for the appraisal results, and should strictly punish those who engage in malpractice intentionally, so as to solve the problem of easy replacement of spare parts.

There is also a problem in the actual operation that maintenance personnel cannot judge the degree of damage of spare parts. For parts that are suspected of failure during maintenance, the maintainer can use substitution method to remove them. If the parts are normal, they must be reinstalled and no new spare parts are allowed. The replacement of spare parts should be recorded accurately, the supervision of spare parts should be strengthened, the use records should be made well, and the average service life should be calculated, so as to reduce the inventory of spare parts, and timely purchase to prevent the shortage of spare parts before they are damaged.

4. Responsibility of maintenance staff

With the extension of air compressor service life, equipment aging is an irreversible fact. The replacement of aging spare parts can be carried out at any time. The replacement of spare parts is largely in the hands of maintenance workers. It is necessary for the maintainer to master the usage of spare parts, roughly estimate the damage time of spare parts, and prepare spare parts for timely replacement before damage, which can not only reduce the maintenance time of equipment, but also avoid the waste of spare parts and reduce the warehouse inventory. This requires the maintainer to have a sense of ownership and a strong sense of responsibility. The leader of the enterprise should pay attention to the maintainer first, so that the maintainer feels sorry for the enterprise if he does not do it seriously.

5. Strengthen 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 the damaged spare parts for the following reasons:

(1) lack of necessary maintenance tools. The original idea was that a mechanic only needed a hammer, screwdriver and a wrench, whereas an electrical maintainer's tools were a multimeter, a needle-nosed pliers, a screwdriver, and a roll of insulating tape. Therefore, the enterprise needs to equip the necessary maintenance tools.

(2) lack of corresponding incentive mechanism. Original management idea thought, mechanic work time for the use of scrap parts is within the scope of work, no maintenance is dereliction of duty, the guy hard to repair a higher price of spare parts, pay a lot of energy and labor, oneself do not have the slightest encourage or reward, their labor and income to pay simply out of proportion, thus lost the enthusiasm of reusing the waste thing. Enterprises should take corresponding incentive measures, according to the price of spare parts, reuse value, reliability, etc., to reward the personnel who repair spare parts at a certain ratio of the price of spare parts, and connect with the evaluation, so as to stimulate the enthusiasm of maintenance personnel for the reuse of waste parts.

6. Strengthen the management of spare parts

Some kinds of spare parts in enterprise spare parts library are insufficient and some kinds are overstocked. It is necessary to set up an upper and lower limit account for common spare parts, which shall not exceed the upper limit or lower limit. Under the condition of normal operation of the equipment, the requirements for normal operation of the equipment and the backlog of spare parts shall not be caused.

7. Extend the service life of components

Technical breakthroughs are encouraged to extend the service life of vulnerable components. Many vulnerable components can be improved through technology to extend their service life, which can also save a lot of maintenance costs.

In many cases, the air compressor factory has tested the product for tens of thousands of hours, and it broke down shortly after it arrived at the user's hand. Users complain that the product is of poor quality - which is actually often caused by the unreasonable use of the user operator.

Many operators boast technical skills, often for the new air compressor equipment lazy to learn operating manual and regulations, think are screw compressors, little difference. In fact, due to the different design, different specifications, different operating conditions, operation and maintenance of the air compressor, there are different requirements. Specialness and lack of detail are often at the root of the failure.

8. Adhere to the daily, weekly and monthly maintenance system

Establish strict maintenance system, urge operators to do strictly according to the regulations, timely deal with the hidden trouble, eliminate the fault in the bud, so as to extend the service life of spare parts. This is particularly important for the lubrication and electrical parts of the supports.

In a word, reducing the maintenance cost of air compressor cannot be solved through one or two efforts. Only through effective combination of all aspects can the problem be completely solved, and it requires persistent persistence to achieve good results.