I. General Provisions
1.1 Objective
Based on the Production Safety Law of the People's Republic of China, Labor Contract Law, and textile industry equipment maintenance basic standards, these guidelines address issues such as high wear part consumption rates, frequent fault-related downtime, and incomplete maintenance records in spinning equipment. The aim is to standardize equipment maintenance operations, reduce failure rates, ensure production continuity, improve overall equipment effectiveness, and control maintenance costs.
1.2 Scope
Applicable to all spinning machines, cleaning machines, ring spinning machines, and other key equipment in the factory. Covers Production Department, Equipment Department, Maintenance Team, and all operators.
1.3 Core Principles
Prevention first, regular maintenance, certified operation, complete records.
II. Organizational Structure and Responsibilities
2.1 Daily Point Inspection by Operators
- Check equipment oil levels and bolt tightness before each shift
- Clean spindle and bearing areas
- Surface must be free of visible oil stains; transmission parts free of dust accumulation
2.2 Planned Maintenance by Equipment Department
- Prepare monthly maintenance plans covering cleaning, lubrication, and component replacement
- Complete Pre-Maintenance Preparation Form with spare parts list and safety measures before maintenance begins
2.3 Fault Response
- Operators must immediately press emergency stop upon discovering faults and notify maintenance team
- Maintenance team must arrive within 30 minutes and complete general fault repairs within 2 hours
- Major faults (such as motor burnout) must be reported to Equipment Department supervisor within 4 hours for spare parts coordination
III. Maintenance Standards and Key Indicators
3.1 Core KPIs
- Overall Equipment Effectiveness (OEE) improvement target: 5%
- Fault downtime rate below 3%
- Spare parts loss rate below 8%
- Maintenance record completeness rate: 100%
3.2 Key Component Standards
- Main Shaft Bearings: Annual inspection required; lubricant replacement every six months using factory-designated models
- Spinning Tension System: Monthly calibration; deviation beyond ±0.5% must be adjusted; all calibration values must be recorded
- High-risk Points: Spindle bearings (annual testing) and spinning tension system (monthly calibration); countermeasures include scheduled lubricant replacement and torque wrench tightening
IV. PDCA Cycle Management
4.1 Plan Phase
- Equipment Department prepares next month's maintenance plan by the 25th of each month
- Plan covers cleaning schedules, lubrication points, component inspection checklists, and resource allocation
4.2 Do Phase
- Operators complete daily point inspection forms
- Maintenance team completes daily work logs
- All maintenance activities must follow standardized procedures
4.3 Check Phase
- Safety officer conducts 3 random inspections of maintenance sites per month
- Equipment Department audits maintenance records quarterly
- Results compiled into Maintenance Work Briefing
4.4 Act Phase
- Annual system effectiveness evaluation in September
- Improvement suggestions submitted by Equipment Department
- Implementation within one month after General Manager approval
V. Continuous Improvement
Process optimization reviews conducted every June and December. Optimization suggestions require dual sign-off from Production Department and Maintenance Team. Simplified plans require General Manager approval with effectiveness evaluation one month after implementation.
