I. General Provisions
1.1 Objective
Based on the Production Safety Law of the People's Republic of China, Product Quality Law, and enterprise lean production strategy, these guidelines address issues such as frequent weaving equipment failures, disordered repairs, and chaotic spare parts management. The aim is to standardize equipment maintenance processes, improve equipment integrity rates, ensure stable production operations, reduce maintenance costs, and prevent safety incidents.
1.2 Core Principles
Persist in the principle of prevention first, equal emphasis on maintenance and repair, individual responsibility, and continuous improvement, combined with equipment-specific requirements for light maintenance and high efficiency.
II. Daily Point Inspection and Cleaning
2.1 Pre-Shift Inspection
- Confirm emergency stop buttons and safety guards are intact and functional
- Apply specified grade grease to all lubrication points
- Check drive components for normal operation
2.2 Post-Shift Cleaning
- Remove oil stains and debris from equipment surfaces
- Keep transmission parts unobstructed and clean
- Record any abnormalities found during operation
2.3 Abnormality Recording
Immediately complete Equipment Abnormality Feedback Form upon discovering abnormalities and submit to team leader for confirmation.
III. Planned Maintenance
3.1 Level 1 Maintenance (Quarterly)
- Comprehensive cleaning of all machine surfaces and internal components
- Tighten all fasteners to specified torque values
- Lubricate all designated points following the lubrication chart
- Adjust belt tensions, chain tensions, and gear clearances
3.2 Level 2 Maintenance (Semi-Annual)
- Replace all wearable parts including belts, seals, and filters
- Adjust equipment parameters to factory specifications
- Coordinate with operators for parameter verification during production
- Document all replacement parts and adjustments made
3.3 Pre-Maintenance Preparation
- Prepare maintenance plan, safety measures, and spare parts list
- Report to workshop supervisor before implementation
IV. Spare Parts Management
4.1 ABC Classification
- Class A (Critical): Core components for key equipment — maintain 3 months usage inventory with monthly inventory checks
- Class B (Common): Regular use items — maintain 1 week usage inventory with quarterly checks
- Class C (Consumable): Routine consumables — maintain minimum stock levels
4.2 Procurement Control
Single purchase under 2000 RMB approved by Equipment Department supervisor; purchases at or above 2000 RMB require General Manager approval. Verify local supplier qualifications and delivery cycles before procurement.
V. Maintenance Recording and Documentation
5.1 Maintenance Logs
Maintenance staff record all activities on equipment log boards adjacent to each machine. Logs are collected by Equipment Department at end of each day.
5.2 Electronic Records
Equipment Department maintains electronic maintenance archives including equipment file numbers, maintenance history, and replacement parts details. Annual backup export by December 31st.
5.3 Performance Basis
Maintenance record completeness and timeliness incorporated into monthly performance evaluation at 20% weight.
VI. Quality Standards
6.1 Core KPIs
- Overall Equipment Effectiveness (OEE) ≥ 85%
- Planned maintenance completion rate: 100%
- Repair timeliness rate: ≥ 95%
- Spare parts loss rate: below 10%
6.2 5S Management
- Sort: Distinguish necessary from unnecessary items
- Set in Order: Fixed position and location for all items
- Shine: Clean equipment thoroughly
- Standardize: Establish standards for cleanliness
- Sustain: Develop habits of discipline
