SHREDDER废钢破碎PPT

ISRIOperationsForumJanuary2007ScottNewellPresidentTheShredderCompany,LLCProblemSolvingForShreddersItisgenerallyagreedthatthebestwaytosolveaproblemisbeforeithappens.Tothatend,wesuggestthatfollowingaplannedprogramofmaintenanceandrepairwillpaybigdividends.Oneofthebiggestassetsthatanyshreddingoperatorhas,isthecollectivememoryoftheteamthatrunstheshredder.Thesearetheguyswhoknowhowtofixaproblembecausetheyhavealreadyfixeditorsomethinglikeitinthepast.PeoplewhodonotattempttolearnfromthosepastmistakesaresadlydoomedtorepeatthemoverandoverAfriendofmine,TobyShine,wasthefirstonetotellmethewisdomoftheoldsaying,“Thedefinitionofinsanityistodothesamethingoverandoverandexpectadifferentresult.”SinceIwasworkingonaproblematthetime,IadmitthatIwasnottoohappywhenhemadethestatementtome,butofcoursehewas100%correct.Ifwearetoavoiddoingthesamethingoverandoverandhavingbadresults,weneedtorecordandsummarizeproblemsandtrytolearnfromthem.Itisveryimportanttohavethatcollectivememoryofhowtofixthings.Itisalsoaverypositivethingtohavemadefriendsintheindustryandtoattendmeetingssuchasthisonewhereitispossibletoexchangeexperiencesandcreatesynergisticrelationshipswherebothpartnersgain.SHREDDERMAINTENANCEEarlyinmycareerIlearnedthevalueofearlydetectionofaproblematashreddingplant.Myfatherhaddescribedtomeaphenomenonknownasthesnowballeffectanditdidnottakeverylongtoidentifyitaroundashredder.Forexample,agearboxisleakinggreasefroma$3.00greasesealandonTuesdayofaparticularweekthedecisionismadetowaituntilSaturdayofthesameweektofixtheproblem(ormorelikelytheleakwasnotevendetected).OnThursdaythegearboxrunsoutoflubrication,thebearingsfail,theshaftlocksupandthegearsareruined.WorkingovertimeandflyingpartstotheplantallowsresumptionoftheoperationonMondaymorningwithonly1-1/2daysoflostproduction.Insteadofa$3.00greasesealand$50.00toinstallit,wenowhavespentthe$3.00foraseal,and$2,000.00forrepairstothegearbox,plusthelossof400or500tonsofproductionthatintoday'smarketwouldhavecreatedatleast$75.00pertonorabout$40,000.00worthofgrossprofit.Thisisthesnowballeffect.Iftherearetoomany“snowballs”thiscanturnintothe“AvalancheEffect”,whichisevenworse.Manytimesascrapprocessingplantisoperatedonademandrepairtypesystem,i.e.,afixit,whenandwhereitbreaksdown,typeofoperation.Withtoday'srequiredcapitalinvestment,sophisticatedmachinery,highproductionschedules,andprohibitivecostsofdowntime,fewcompanieswantto,andevenfewercanaffordto,operateinthismanner.Aplannedpreventivemaintenanceprogramrequiresthededicationofthetopmanagementtoseethattheproperpeople,systems,andtoolsareselected.Individualswithevenlimitedmechanicalabilitycanbetrainedtoadequatelymakerepairsandtoserviceequipmentwhenimpressedwiththenecessityofplantmaintenancebyanenlightenedsupervisor.HowdoI,asanexecutive,makesurethatmysystemisfunctioninginasatisfactorymanner?GeneralObservationsOneofthebestmethodsofevaluatingyourplant'splannedpreventivemaintenanceprogramistohavetheshredderoperatorkeeprecordsofuptime,downtime,andplannedmaintenancetime.Modernshreddingplantshavesometypeof“SmartShreddingSystem”thatrecordsandkeepstheserecordsautomaticallyinacomputer.Ask,Why?Nomatterhowgoodyourmaintenancesuperintendentis,theplantseemstofunctionbetterwhenthebossknowssomethingaboutwhatneedstobedone.Therefore,payattentiontowhatyouseeandconstantlyaskyourselfandothersWhy?,e.g.,Whyisthereapileofscrapnexttothebottomoftheconveyor?Usually,thisindicatesawornormissingskirtboardorsomethingequallyobviousifyougotolookforthewhy?.ObservationandaskingWhy?manytimeswillstopthatsnowballeffectimmediately.Otherthingsforwhichtolookandotherthingsaboutwhichtoaskwhy?are:•Oilleaks•Waterleaks•Vibrations•Loosebolts-youcangenerallyspotalooseboltwithouttouchingit.Thereis,mostofthetime,alinevisiblebetweenthenutandthesurfacethatitispullingagainst.•Brokenbolts-lookatthebrokenboltandtrytodeterminewhethertheboltfailedinshearorwhetheritfailedfromfatigue.Thiswillhelpyoutopreventthenextboltfrombreakinginthesamemanner.•Brokenorcrackedsteelstructures.•Holesinductworkorcyclones.•Alignmentofbeltsandchains.•Loosesprockets(again,lookforthevisiblelineofadjoiningsurfaces).•Brokenand/orleakinggearboxes.•Looseelectricalwires.•Openelectricalpanels-thismaymeanthatamotorisoverloadingandthatapatchartistiskeepingtheresistorscoolertoavoidcomingoffthelineelectrically.Thisisjustgreat,exceptthatshortlyyouwillbeburningouttheelectricmotor,tosaynothingofthedangertopersonnelofleavingtheboxopen.Keepinginmindthatmostexecutivesarenotmechanics,wehavepreparedachecklisttohelpyoucontrolandverifythatyouarestoppingthesnowballeffectasquicklyaspossible.DAILYPRODUCTIONREPORTPlant:________________________Date:_________________________Operator:_______________________WeatherConditions:____________________________________________StopStartLengthofExplanationdelay________________________________________________________________________________________________________________________________________________________________________________________________________________________________