维修工作流程图及说明

1、MaintenanceWodczowMECH2014总07mf2014维修流程介绍IntroductionofMaintenanceProcess维修业务工作流程Maintenancebusinessworkflow：年/季/月(1+3)计划维修工作流程Workflowforannual/quarterly/monthly(1+3)plannedmaintenance 日常故障维修工作流程Dailyfailuremaintenanceworkflow 非计划维修工作流程UnplannedmaintenanceworkflowFREP所有维修工作都是按照这三个工作流程开展的。Allmainten

2、anceworksofFREParecarriedoutaccordingtothesethreeworkflows.年/季/月度计划维修工作流程图变更项目申请调整项目/概算WorkFlowDiagramforAnnual/Quarterly/MonthlyPlannedMaintenanceApplicationforprojectchangeMCLBTMMaintenanceplannerDevelop(1+3)four-weekplanAdjusttheproject/budget维修工作流程图维修计划员；外操人员MCLMCL筛选通知检视工作理由比较其他选择沟通筛选结果，下达工作指令确认

3、工作范围检视最佳工作时间根本性故障原因分析处理通知单（DOAG）批准（概算/工期）现场确认并准备具体工作范围制订材料/机具/资源需求工作要求录入ERP成本测算计划有效性确认维修计划主管/维修计划员维修计划员维修班长维修计划员工作关闭编制工作包协调工作准备编制工作排序编制周/日资源分配计划批准米购申请DOAG）沟通循环女全管理管理界面协调监督工作执行较复杂项目编制执行表现报告工作计划提升点反馈至维修计划员及工程师超概算标准工作包数据库维护延期/拒绝建议：缩小范围/调整概算紧急事宜（关键设备故障）备注：1.一般设备不必注明交付工期，由计划员根据SDD及资源情况进行排序。2.维修计划员在成本测算及制

4、订施工资源需求时，应参考相关合同及相关定额。MaintenanceWorkFlowDiagramQuarterly/monthly/weeklymaintenanceplanFieldoperatorsPCLMCLMaintenanceMaintenanceplanMaintenanceplannersupervisor/PlanerFailurenotificationfillsinERPScreeningConfirmnotificationsbestworkCheckscopereasonsforInspectwork*bestworkScreentimealternativesRoot

5、Communicatecauseselectionfailureresults,giveanalysisinstructionsMCLHandlenotification(DOAG)Approve(budget/constructionperiod)CommunicationcyclevConfirmonsiteandpreparespecificworkscopeDevelopmaterials/machines/tools/resourceneedWorkisrequiredtobeenteredintoERPCostestimationPlaneffectivenessconfirmat

6、ionApproveprocuremerrequisition(DOAG)riabri-riba-riBbviplannerDevelopjobpackageCoordinateworkpreparationDevelopworkprocedureDevelopweekly/dailyresourcesallocationplanMaintenanceTeamleadSafetymanagementManagementinterfacecoordinationWorkexecutionsupervisionImplementationperformaneereportdevelopmentfo

7、rrelativecomplexprojectFeedbacktheworkplanimprovementpointstothemaintenanceplanerandtheengineersDelay/declineOverrunofbudgetiRecommendation:narrowdown：scope/adjustbudgetStandardjobpackagedatabasemaintenanceEmergencymatters(Criticalequipmentfailure)MaintenanceplannerWorkClosureNote:1.forgeneralequipm

8、ent,itisnotnecessarytoindicatethedeliverableconstructionperiod,buttheplannerneedstoprioritizethemaccordingtoSDDandresourceavailability.2.Whencalculatingthecostandpreparingresourcerequirementsforconstruction,themaintenanceplannershallasperrelevantcontractsandrelevantregulations.非计划维修工作流程图操作人员PCL/MCL/

9、总调BTMMCLWorkflowDiagramforUnplannedMaintenanceOperatorPCL/MCL/ShiftSuperintendentBTMMCLEnterplan/*Implementationprocess工作流程说明ExplanationonWorkProcess一、年度/月度计划维修工作流程Annual/Quarterly/MonthlyPlannedMaintenanceWorkProcess1. 年度维修计划由年度大型维修项目及常规预防性维修项目、改良性项目、大修项目等组成。MCL组织各专业工程师根据五年规划要求、设备策略、运行设备可靠性分析及高故障率设

10、备清单等编制年度大型维修项目清单，BTM组织业务团队内部讨论（MCL、PCL、TCL、安全工程师参加）筛选后，报机械设备部维修计划主管汇总。AnnualMaintenancePlaniscomposedofannuallarge-scalemaintenanceprogram,routinemaintenanceprogram,improvementprogram,overhaulprogramandetc.MCLshallorganizeeachdisciplineengineertodevelopannuallarge-scalemaintenanceprogramaccordingtot

11、hefive-yearplanrequirements,equipmentmaintenancestrategy,equipmentreliabilityanalysisandhighfailureequipmentlistandetc.,andBTMshallorganizebusinessteamsforinternaldiscussion（MCL,PCL,TCLandsafetyengineersparticipate）andselection,whichshallbesubmittedtotheplanningsupervisorofMechanicalDepartmentforsum

12、mary.2. 机械设备部维修计划组参照历年同类装置维修费用使用、设备运行趋势进行费用综合测算（包括业界对比适时情况、公司下一年度维修预算展望），双方并就工作单优化及年度初步预算达成一致于每年8月中旬前完成公司年度维修计划初稿上报MLT审查。MaintenancePlanGroupofMechanicalDept.shalldevelopcomprehensiveexpensebudgetingaccordingtoyear-on-yearmaintenanceexpensesandequipmentrunningconditionsovertheyears（includingapplicab

13、lebenchmarkingdataandthenext-yearmaintenancebudgetoutlook）;andreachanagreementwithBTsonoptimizationofworklistsandpreliminaryannualbudget.MaintenancePlanGroupofMechanicalDept.developsdraftofAnnualMaintenancePlanfortheCompanybythemiddleofAugustandsubmitsittotheMLT.3. MLT组织相关职能部门讨论定稿后上报公司董事会（BOD）审批执行，如

14、MLT对年度计划项目或概算有调整则需返回业务团队重新优化后报批。MLTorganizediscussionsamongrelevantfunctionaldepartments,finalizethedraftandsubmittoBODofthecompanyforapprovalandimplementation,ifMLThasanyadjustmenttowardsannualplannedprojectorbudgets,thenthedraftshallbereturnedbacktobusinessteamsforoptimizationandthensubmitforappro

15、val.4. 机械设备部维修计划主管根据年度业务计划编制三月维修计划展望（包括成本估算、执行时间建议），该计划要结合全厂资源管理，计划工作延迟管理等情况进行滚动编制，每月更新一次。MaintenancePlanGroupSupervisorofMechanicalDept.developsoutlookforquarterlyplan（includingcostestimation,suggestionsofexecutiontime）.TheplanshallbedevelopedinarollingwaybycombiningthePlant-wideResourceManagementa

16、ndplanworkpostponementmanagement,whichshallbeupdatedonamonthlybasis.5. 业务团队MCL根据月、季度成本/预算对计划进行审核、沟通，优化计划执行，如需对批准的项目变更、替代或追加项目或申请预备金等则需由MCL申请，由MLT审批后方可执行。BusinessTeamMCLshallreview,communicateandoptimizetheimplementationoftheplanaspermonthly/quarterlycost/budget,ifitisnecessarytochange,replaceoraddit

17、ionalprojectorapplyreservefundfortheapprovedproject,MCLshallsubmittheapplication,andwillbeputintoimplementationaftertheapprovalbyMLT.二、维修工作流程MaintenanceWorkProcess1计划协调：维修计划员根据各项工作准备（包括材料交货时间/资源情况），编制（1+3）周工作计划排序，在周四维修计划会提交讨论，已总结上周计划完成情况及安排下周工作安排，滚动更新（1+3）并于每周五发布执行。Coordinationofplan:maintenanceplan

18、nershalldevelopworkplanorderof（1+3）weeksaccordingtoallpreparations（includingdeliverytimeofmaterials/enterpriseresource）;completionstatusofplanforthelastweekandworkarrangementforthenextweekshallbesubmittedanddiscussedatthemaintenancemeetingheldonThursday;itshallbeupdated（1+3）inarollingmannerandissued

19、forimplementationonFriday.2. 工作申报：外操人员在ERP系统录入故障通知单（计划通知单由计划员录入）。Requestofwork:MaintenancePlannerissuesweeklyplannedmaintenancenotificationsheet（unplannedfailureisnotifiedbyoperator）.3. 工作筛选：PCL对工作通知进行筛选，检视作业理由及比较其他选择，确定工作选择；MCL确定工作范围及最佳工作时间。PCL与MCL之间将就工作选择不断沟通协调优化，同时要对故障进行根本性原因分析，MCL在ERP上对通知单进行处理，处

20、理意见有：延期/拒绝/批准。Selectionofwork:PCLscreenstheworknotification,inspectsworkreasonsandcomparesotherselectionstodeterminework;MCLconfirmsworkscopeandbestworktime;PLCandMCLmakecontinuouscoordinationandoptimizationforworkselectionthroughcommunication,andanalyzetherootreasonsoffailure,MCLshallhandlethenotif

21、icationinERPsystembasedonthefollowingopinions:propones/refuse/approve.4. 工作审批：MCL（根据授权）对需要执行的通知单进行工作清单审批（包括概算、可接受的交付时间要求）一般设备不必注明可交付工期，由计划员根据SDD及资源情况进行排序。Approvalofwork:MCL(basedonDOAG)needstoapprovetheworklistinrespectoftheworkordertobeimplemented(includingbudgetaryestimateandacceptabletimerequest)

22、;forgeneralequipment,itisnotnecessarytoindicatethedeliverableconstructionperiod,buttheplannerneedstoprioritizethemaccordingtoSDDandresourceavailability.”6. 工作编制：Developmentofwork:A计划员根据审批的工作清单以及季/月/周计划进行现场确认，编制具体工作范围描述、成本测算，制定具体的施工材料、施工机具及资源需求并录入ERP；施工资源需求按照合同履行，成本测算按照相关定额进行，需求策略维修计划组负责统筹询价采购申请并安排。如

23、果超概算则由计划员提出相关建议：如缩小范围、调整概算等，返回MCL重新审定。符合概算由维修计划员/维修计划主管(DOAG)批准进行采购申请(包括材料采购及服务采购)。Plannermakeconfirmationonsitebasedonworklistapproved,preparesdescriptionofspecificworkscopeandcostestimation,anddevelopsspecificconstructionmaterials,constructionmachines&toolsandresourcesdemandwhichshallbeentered

24、intoERP;theresourcerequirementforconstructionshallbeimplementedasperthecontract,andthecostcalculationshallbeconductedasperrelevantquota;DemandStrategyMaintenancePlanningTeamshallsummarizetheinquiries,purchaserequestandmakearrangements.Incaseofover-budget,plannershallproviderelevantsuggestions:suchas

25、narrowingdownscope,adjustingbudgetandetc.,whichshallbereturnedtoMCLforre-check.Ifthejobcomplieswithbudget,MaintenancePlannerorMaintenancePlanSupervisorwillapprovetheprocurementrequest(includingmaterialpurchaseandservicepurchase).A维修计划员编制工作包，协调工作前准备，编制周/日资源分配计划及工作排序。按照月计划编排好最新第一周排序(包括故障维修计划)并释放，维修班长安

26、排实施(其中第一周的工作已完全安排好并包含其中工作的每日时间表)，四周时间表还提供第2至4周的综合工作时间表，以便及时为这些工作做好必要的准备，另对标准工作包数据库进行维护。Maintenanceplannershallpreparetheworkpackageandcoordinatethepreparationsbeforework,prepareweekly/dailyresourcesdistributionprogramandworkorders.Preparetheordersofthefirstweek(includingmaintenanceplanoffailures)bas

27、edonthemonthlyplananditsassignments.Shiftleadofmaintenanceteamshallberesponsiblefortheimplementation(amongwhich,thejobsofthefirstweekhavealreadybeenarranged,andincludethetimescheduleofeachday),provideworkschedulesofthefourweeksandthecomprehensiveworkscheduleformweek2toweek4soastomakethenecessaryprep

28、arationworktimely,andberesponsibleforthemaintenanceworkforstandardworkdatapackage.7. 工作执行：维修班长将每项工作安排到执行班组，进入作业票办理。Executionofwork:shiftleadofmaintenanceteamshallarrangeeveryjobtotheresponsibleshift,andenterintotheprocessofworkpermit.A按照日计划安排，作业人员于前一天下午通知作业票协调员开具作业票(包括动火、用电等)，发出作业需求。Accordingtothesc

29、heduleofworkpermit,theoperatorsshallinformworkpermitcoordinatortoissueworkpermit(includinghotworkandelectricitypermit)ontheafternoonbeforework,delivertherequirementtowork.A作业票协调员根据作业内容进行作业票填写签发，操作人员根据作业票详细要求进行逐项落实确认于作业当天上午8点前完成该项工作。Workpermitcoordinatorshallfillinandissuetheworkpermitaspertheworking

30、content,andtheoperatorsshallconfirmitembyitemaccordingtothedetailedrequirementsofworkpermit,andsuchconfirmshallbecompletebefore8'clockonthedateofworkpermit.A维修人员施工前对作业票确认签字后开始实施作业，项目作业完成后由维修班长及倒班班长共同对作业票进行签字确认关闭。Maintenanceworksshallsignontheworkpermitbeforework,maintenanceleadandshiftleadshalls

31、ignandclosetheworkonworkpermitaftertheworkiscomplete.A维修班长要进行安全管理、管理界面协调，协调安排工作、监督工作执行，工作量确认(不超计划量，如超计划必须及时沟通计划员)及较复杂项目完成执行报告，关键工单拖延/提前应及时与维修计划员协调，对于工作提升建议需反馈维修计划和可靠性工程师。Maintenanceleadshallperformsafetymanagement,managementinterfacecoordination,jobcoordinationandsupervisetheworkimplementation,confi

32、rmtheworkquantity(donotexceedthescheduledquantity,andshallcommunicatewiththeplanerstimelyifitexceedthescheduledquantity),andprepareimplementationreportforcomplicatedworkitems,coordinatewiththeplannertimelyifkeyworkorderispostponedorbroughtforward,andshallfeedbacktheworkimprovementsuggestionstomainte

33、nanceplanningandreliabilityengineers.A维修计划员在ERP上对工单完工确认并关闭。MaintenanceplannershallconfirmandcloseworkorderinERPsystem.注：按照授权指引分别授权给MCL和BTM进行ERP工单审批，费用超过(按授权指引)需提交MLT讨论批准(线外书面审批)，由MCL在ERP上完成审批流程。Note:ApprovalauthorityofERPworkorderisdelegatedtoMCLandBTLbasedonDOAG.Forworkorderswithextremelylargecost(

34、tobedetermined),theyshallbesubmittedtoMLTfordiscussionandapproval(offlineapprovalinwriting)andMCLgoesthroughapprovalprocedureinERP.三、非计划维修工作流程UnplannedMaintenanceWorkProcess1. 因功能故障而需进行的非计划检修，应该仅适用于事先确定的关键设备/紧急事件，一旦发生由操作人员发出通知单报告PCL/MCL/生产总调。Unplannedrepairduetofunctionalfailuresshallonlyapplytokeyequipment/emergencyeventswhicharedeterminedinadvance.I