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GB/T 41251-2022 English PDF (GBT41251-2022)

GB/T 41251-2022 English PDF (GBT41251-2022)

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GB/T 41251-2022: Production process quality control - Life cyclemanagement of production equipment

This Document specifies the full life cycle stages, full life cycle management model, full life cycle management tasks, full life cycle management requirements and information management of production equipment based on the production process quality control requirements.
GB/T 41251-2022
NATIONAL STANDARD OF THE
PEOPLE REPUBLIC OF CHINA
ICS 25.040
CCS N 19
Production Process Quality Control ?€?
Life Cycle Management of Production Equipment
ISSUED ON: MARCH 09, 2022
IMPLEMENTED ON: OCTOBER 01, 2022
Issued by: State Administration for Market Regulation;
Standardization Administration of the PEOPLE Republic of China.
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative References ... 4
3 Terms, Definitions and Abbreviations ... 4
3.1 Terms and Definitions ... 4
3.2 Abbreviations ... 6
4 Full Life Cycle Stages ... 6
5 Full Life Cycle Management Model ... 7
6 Full Life Cycle Management Tasks ... 8
7 Full Life Cycle Management Requirements ... 9
7.1 Planning management ... 9
7.2 Design and manufacturing management ... 10
7.3 Installation and commissioning management ... 12
7.4 Operation and maintenance management ... 12
7.5 Rejection management ... 18
8 Full Life Cycle Management Informatization ... 20
8.1 Overview ... 20
8.2 Content ... 20
8.3 Tasks ... 21
Production Process Quality Control ?€?
Life Cycle Management of Production Equipment
1 Scope
This Document specifies the full life cycle stages, full life cycle management model, full life cycle management tasks, full life cycle management requirements and information management of production equipment based on the production process quality control requirements.
This Document is applicable to the full life cycle management of production equipment related to the industrial production process; and provides a basis for industrial enterprises to carry out the full life cycle management of production equipment.
2 Normative References
The provisions in following documents become the essential provisions of this Document through reference in this Document. For the dated documents, only the versions with the dates indicated are applicable to this Document; for the undated documents, only the latest version (including all the amendments) is applicable to this Document.
GB/T 37393-2019 Digital Factory - General Technical Requirements
GB/T 41272-2022 Production Process Quality Control - General Interface for Quality Data 3 Terms, Definitions and Abbreviations
3.1 Terms and Definitions
For the purposes of this Document, the following terms and definitions apply. 3.1.1.1 Equipment
The general term for the equipment, equipment systems and their supporting technical equipment, etc., which are used to implement and guarantee production and operation activities. NOTE: In some specific scenarios, equipment can also be directly referred to as device. 3.1.2 Equipment full cycle
The full life cycle time for the equipment from planning studies, through design and manufacture to use and disposal.
NOTE 1: It usually includes the whole process of planning and demonstration, design and manufacture, bidding and procurement, installation and commissioning, operation and maintenance, repair and transformation, and disposal until rejection.
NOTE 2: The equipment life cycle can also be called the equipment life cycle [Translator Note: it is the same in English].
NOTE 3: According to the occurrence sequence of management tasks, the management of equipment life cycle can be divided into three stages: preliminary management, operation and maintenance, and update and rejection.
3.1.3 Equipment maintenance
In order to prevent the deterioration of equipment performance or reduce the probability of equipment failure, the technical management measures that are carried out according to the pre- specified plan or the provisions of the corresponding technical conditions. NOTE: Equipment maintenance can also be understood as "equipment caring". The core work of equipment maintenance (caring) is cleaning, such as: blowing, vacuuming, wiping, washing, descaling or replacing. Use the opportunity of maintenance (caring) to conduct: lubrication, adjustment (for temperature, position, pressure, speed, flow, tightness, clearance, etc.), tightening, anti-corrosion, inspection, elimination and replacement (consumables or wearing parts). 3.1.4 Organization
An organization that operates production equipment to complete production and manufacturing activities and is responsible for the management of the equipment life cycle. 3.1.5 Preventive maintenance
Scheduled activities that are planned to eliminate the causes of equipment failures and unplanned production interruptions (periodic inspection and maintenance based on equipment operating hours).
3.1.6 Predictive maintenance
A method or set of techniques for analyzing and evaluating the condition of in-service equipment through periodic or continuous monitoring of equipment condition. NOTE: Time that is used to predict when the next failure shall occur and the specific time for maintenance.
3.1.7 Periodic overhaul
carried out for equipment that has reached its service life, has frequent failures, and affects the quality of the production process.
7 Full Life Cycle Management Requirements
7.1 Planning management
7.1.1 Planning and selection
When organization conducts the equipment planning, it shall proceed from business strategy and objectives, and consider the needs of production and market demand, new product development, safety and environmental protection, life cycle costs, etc.: --- The equipment user organization, equipment management organization, quality management organization, public engineering organization and IT management organization shall participate in the equipment planning and selection demonstration; --- The evaluation elements for equipment selection decision-making shall be clarified, and the multi-index weighted comprehensive evaluation and ranking shall be carried out on the candidate equipment and suppliers;
--- According to the technological requirements and market supply conditions, a variety of optional schemes shall be proposed, and the required equipment shall be selected and purchased from the optimal products in accordance with the principles of advanced technology, economical rationality, applicable production, safety and reliability, and promotion of technological progress of the enterprise;
--- After the demonstration, the planning and selection records and final conclusions shall be formed.
NOTE 1: The indicators of equipment economic evaluation include the full life cycle cost, etc. NOTE 2: The technical evaluation indicators usually need to evaluate the following factors of the equipment, such as safety, environmental hazard, process adaptability, performance or parameter comparison, reliability, operability, maintainability, repairability, general interchangeability, energy saving and consumption reduction, recyclability, easy installation, equipment service life, spare parts supply, after-sales service, regulatory compliance, energy conservation, user credibility, as well as the main things to pay attention to when using the same type of equipment.
7.1.2 Bidding and procurement
The organization shall specify the following applicable equipment bidding and procurement requirements:
--- According to the results of equipment planning and model selection demonstration, clarify the procurement method of equipment;
--- In the bidding or procurement documents, specify the technical requirements, delivery requirements, arrival acceptance, post-commissioning acceptance requirements, technical training, technical data, abnormal handling, after-sales service, responsibilities of both parties and other requirements for the equipment, as well as the qualification requirements for supplier.
NOTE 1: The organization can adopt the procurement method combining bidding procurement and directional procurement, that is, on the basis of fully understanding its performance and price ratio through bidding and procurement method, determine a brand; fix the procurement channel; conduct fixed procurement during the procurement period when the company is expanded or production is expanded, as well as the product upgrade.
NOTE 2: Equipment technical requirements refer to the name, specification, model and quantity of the equipment, functional requirements of the equipment, equipment reliability, operability, maintainability, repairability, technical parameters, adoption standards, process and materials requirements for the main components of the equipment, random spare parts tools, equipment safety protection device requirements, main technical requirements, life requirements, equipment energy requirements, environmental requirements, etc. When applicable, the applicable international, national or industry standards may be cited as equipment technical requirements.
NOTE 3: Technical training refers to the technical training requirements for the use, maintenance, checking, lubrication and repair of equipment.
NOTE 4: After-sales service, such as: initial operation supporting production service requirements, warranty period requirements, technical support requirements and equipment program software upgrades, etc.
7.2 Design and manufacturing management
7.2.1 Supervision and management
The organization shall meet the following requirements in terms of supervision and management:
--- For larger equipment or equipment systems requiring design improvements or changes by the equipment manufacturer, follow the organization's relevant outsourcing procedures;
--- When applicable, the organization should refer to the national standards and industry standards related to equipment supervision to standardize the management requirements for equipment supervision, and clarify the following applicable requirements: ??? The scope of equipment supervision and its corresponding equipment manufacturing quality supervision methods;
NOTE: The work content of the arrival acceptance usually includes the participants, the acceptance location, the acceptance time, the acceptance content, the acceptance method, the acceptance standard, the acceptance record, and the handling method when the acceptance does not meet the requirements. Among them, "acceptance content" usually refers to the items specified in the contract and packing list. 7.3 Installation and commissioning management
7.3.1 Installation and Commissioning
The organization shall meet the following requirements in terms of installation and commissioning:
--- Ensure that all the preparatory work before installation is in place, do the basic construction according to the technical data such as the equipment process layout plan; and accurately position the equipment installation;
--- Ensure that the installation process is carried out in accordance with the construction specifications;
--- After installation, carry out equipment verification through trial operation (including: idling test, load test, accuracy test, etc.).
7.3.2 Equipment acceptance
The organization shall meet the following requirements in terms of equipment acceptance: --- After equipment commissioning and verification are qualified, carry out the final acceptance of the equipment installation project; and go through the equipment handover procedures after the acceptance is passed;
--- Designate relevant posts to participate in the installation and acceptance of the equipment to ensure compliance with the requirements of the contract and technical agreement (focusing on: checking the compliance of the main technical parameters of the equipment and the quality requirements of the production process);
--- When the acceptance is passed and the equipment is handover, the installation acceptance record shall be kept;
--- After the equipment is checked and accepted, establish the equipment management card and the fixed asset equipment ledger; and ensure that the corresponding acceptance data and records of the equipment are stored in the equipment file.
7.4 Operation and maintenance management
7.4.1 Equipment operation
The operation and maintenance management of equipment shall meet the requirements of 10.6 in GB/T 37393-2019. In addition, the organization shall meet the following requirements. --- Establish equipment safety operation procedures or standardized operation videos, as necessary. The operating procedures are easy for equipment users to understand and are operable to ensure that a valid version of the procedures can be obtained at the posts that need to use.
--- For the new equipment of the enterprise, the technical personnel of the equipment manufacturer shall train the equipment operation and maintenance personnel before the equipment is put into operation. The content includes equipment principle, structure, operation method, safety precautions, maintenance knowledge, common problems and disposal, etc.
--- The operators have been trained and qualified to take up their posts. The training content includes the identification and training of equipment technical performance, principle- overview, operation method, abnormal situation and emergency failure handling ability. --- The operator shall operate according to the equipment operating procedures and the technical performance and requirements of the equipment.
--- Equipment users and related personnel, if they are unable to deal with problems such as abnormalities and defects found in the use of equipment, they shall timely notify relevant personnel to deal with them according to the procedures, methods and requirements specified by the enterprise; and record the problem information and handling conditions according to the provisions of the enterprise. The information is usually recorded in the equipment operation record sheet, checking record, shift record, working log or information system.
--- Standby equipment shall be switched or jiggered according to the cycle specified by the enterprise.
--- The equipment with interlocking self-start and stop ensures normal function. --- If there are qualification requirements for equipment operation, the operator shall meet the relevant requirements.
--- When the equipment operates in a multi-shift system, the equipment user shall specify the management requirements for equipment shift handover; and if there is a problem with the equipment, it shall be recorded in the shift handover record truthfully and in a standardized manner.
--- If there are regulations for the enterprise to record the use or operation of equipment, the equipment users shall record it truthfully and on time.
--- In order to ensure that equipment users can operate the equipment in a standardized manner and record as required, the equipment user department shall do a good job for materials;
--- Ensure that spare or decommissioning equipment is well maintained and ready to be activated;
--- When the organization outsources equipment maintenance, the organization reviews the outsourcing process, implements it after approval; and supervises and evaluates the equipment maintenance service provider;
--- The personnel in equipment use and equipment management shall supervise and inspect the implementation of equipment maintenance and make assessments as necessary to ensure the effectiveness of equipment maintenance and management.
NOTE 1: Equipment maintenance outsourcing can be both parties under the same legal person organization, or both parties of different legal entities, who stipulate the responsibilities to be performed by both parties through contracts or agreements; and determine the requirements for scope, responsibilities, personnel, profession, technology, quality, safety, environment, cost and other indicators of the outsourcing.
NOTE 2: Equipment maintenance procedures, usually covering (but not limited to): equipment name, division of labor, cycle or timing, location, content, standards, methods, means and tools, maintenance acceptance, etc.
NOTE 3: The annual equipment maintenance schedule includes serial number, equipment number, equipment name, maintenance (and or) overhaul location, main maintenance/overhaul content, cycle, responsible post, planned maintenance month, tabulator and date, reviewer and date, the cell color distinction between plan and implementation (plan = yellow, executed = green), table number and version identification number, etc.
7.4.3 Equipment aging management
The organization shall establish, implement and maintain an equipment aging management process to ensure the availability of equipment spare parts. The process includes the following requirements:
--- Establish a spare parts management mechanism (focusing on: classification, coding, inventory model, planning, approval, procurement, acceptance, storage, in-out inventory, localization, repairing old parts, remanufacturing, objection processing and economic index data analysis and summary, etc. of the spare parts); and work shall be carried out in accordance with the spare parts management system;
--- Pursue the need for equipment maintenance with the least spare parts funds and reasonable inventory reserves; and continuously improve the reliability of equipment and the economy of maintenance;
--- Using data analysis methods to optimize the spare parts inventory model, safety stock, quantity of bulk purchases, etc., and control the amount of spare parts inventory; --- Standardize the contract management of spare parts procurement;
--- Establish a spare parts quality objection handling mechanism;
--- Strengthen the management of spare parts warehouse (focusing on: warehouse area layout strategy, storage location planning, selection of suitable storage facilities such as shelves, spare parts location coding, maintenance of warehouse environmental conditions, FIFO, spare parts account and material in-out inventory management, spare parts storage and management, etc.);
--- Continuously improve the management, visualization and customization levels of spare parts warehouse.
7. 4.4 Equipment check management
Organizations should meet the following requirements for equipment check. --- Formulate management measures for equipment check; clarify management requirements (focusing on: organizational structure, division of responsibilities, professional check personnel training and check standard preparation, check plan formulation, check work performance evaluation and incentives, etc.); establish a closed- loop mechanism for continuous improvement.
--- According to the requirements of equipment performance, process and safety, etc., formulate check standards (crucially combine: equipment technical instruction data, equipment maintenance technical standards, check work experience, failure historical data, etc.); including ensuring that the newly-added and renovated equipment have formulated or updated the effective check standard before the equipment is put into operation.
--- Compile the check plan (compiling basis: check standards, lubrication operation instructions, equipment status, check workload, etc.), to ensure the timeliness, accuracy and effectiveness of the check plan, and to be effectively implemented of it. --- Ensure that equipment abnormalities or hidden dangers found in the check can be dealt with in a timely manner.
--- By recording, analyzing and summarizing the check data and check information, master the equipment status and the trend of deterioration development. If necessary, adjust the check items in a timely manner; and establish a database of equipment failure information found by the check work.
--- Through the summary and analysis of the check work, the problems in the equipment manage...

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