Alternative thinking of ABC management of printing equipment parts
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In recent years, the printing industry has developed rapidly, and the introduction of printing equipment is one of the outstanding performances. It is necessary to give full play to the production efficiency of printing equipment, especially imported large-scale printing equipment, and to purchase and manage parts and components is an important part. In this process, we must pay attention to the commonality of parts and components as material management, but also pay attention to its particularity. On the one hand, parts and components as the material materials of enterprises should be purchased and managed according to the basic principles of material management; on the other hand, parts and components can only play a role when equipment failure occurs, so there is a big difference with production materials. . The ABC classification management method is a very effective method. Of course, parts and components have their own particularities and cannot be completely copied. Here we discuss the management of printing equipment components in accordance with the ABC classification management method. Some of these ideas are somewhat different from traditional theories, so let's call them alternative thinking.
The particularity of printed parts
The ordering of parts for most imported printing equipment takes a long time, and maintaining a certain amount of stock is necessary to ensure the continuity of production. According to the ABC management method, the classification of management is mainly based on value and quantity, and the management object with small quantity and high price should be paid attention to. However, the value of printing equipment components in the enterprise is not completely related to price, and the value in production is often not proportional to the price or even irrelevant. We often encounter this phenomenon in our work. A small and low-priced part fails, often affecting the entire production. Therefore, in the classification management of parts and components, the primary consideration is the impact on production, and the value is second.
Paper, PS plate, blanket and other materials are commonly used in the production of enterprises. Various materials will be used sooner or later in the production of the enterprise, so that they can be directly converted into costs. The value and price in the production are directly related to the price. . The parts are different. If a low-priced part is not in stock, problems can not be replaced in time, which may greatly affect the production; and purchase a high-priced part of the stock, if the device does not have this device If there is a problem, it will not work in production. Further, if the equipment has no problems throughout its life cycle, this spare part has no value. This is the biggest difference between the value of parts and materials in the enterprise, and the greatest particularity of the parts of printing equipment.
Principles of component ABC management classification
The timeliness of rotary printing production is very strong. Here, the classification principle of the ABC management method for printing equipment parts is discussed by taking the printing production line of the large newspaper unit as an example.
1. Impact on production
The impact on production is the main aspect of evaluating the value of the components within the company. For large mechatronic systems, components can be divided into global components, unit components, and color group (local) components. A problem with the global components will stop the entire production line, and the unit components will affect one unit, and the color unit will only affect the operation of one color group. Different parts have different degrees of influence after failure.
In the increasingly complex large-scale rotary machine, the electronic system plays an increasingly important role. It has become the nerve center of the equipment, and its failure has become a major factor affecting the stable operation of the equipment. In order to efficiently manage parts and components, the procurement and management of electronic system components should be placed in a prominent position.
The modernization of electronic equipment has become increasingly prominent, and mechanical components have been greatly simplified. For example, in the shaftless transmission technology, mechanical components are more replaced by electronic systems, and the mechanical components retained are more important. As a large-scale mechanical equipment, there are always some components that are damaged prematurely during use. The main reason is that the design is unreasonable or improperly used, and the former is the main reason. Mechanically speaking, the machining process has been quite mature after several hundred years of development, and its service life should exceed the life of the entire equipment; from the influence degree, most mechanical parts play a partial role. Therefore, the procurement and inventory of mechanical parts must be very careful.
2. The probability of failure
The enterprise value of the parts needs to have an opportunity to reflect, which involves the probability of failure. In parts procurement management, efforts should be made to avoid parts that are not required for procurement and inventory.
For component management, the most important task is the probability of component failure. This is a key factor in determining whether parts are ordered or not. A more important component is worthless if it does not fail at all during the life of the device. Some parts that often fail, although the value is not high, but if there is no replacement of parts, it will have a great impact on production, so it needs to be given special attention. An important part of daily equipment component management is to analyze and understand the probability of failure of various components to determine parts inventory and procurement time.
It should be noted that from the actual maintenance situation of each factory, it can be seen that the same equipment has certain similarities in component failure, but there are certain differences, which are related to the different manufacturing and use of equipment. In addition, as the component manager of the equipment, it is not possible to determine the purchase and inventory of parts by experience alone, and it is necessary to strengthen the data collation and analysis, and require detailed records of each failure, so as to analyze based on this. At the same time, pay attention to multi-directional equipment operators and maintenance personnel to understand the situation and listen to opinions and suggestions.
3. Price
After the introduction of a set of equipment, the price of the parts is much lower than the equipment itself. It is often the case that once this component is not procured and stocked, the impact is often far greater than its own price when it is in question, which is most evident in imported equipment. However, the ultimate goal of the ABC classification management of components is to achieve better economic benefits, so we must also pay attention to the price of components and put them into the classification basis.
4. The difficulty and time of component replenishment
Domestic large-scale modern printing equipment is mostly imported products, and some parts require time to order. However, with the increase in the introduction of equipment, large international manufacturers have begun to pay attention to improving the supply form of parts and components. Some manufacturers have adopted the method of bonded warehouses, so that the domestic also has a certain amount of common parts and components, which is convenient for users. Therefore, for some parts that are not used often, you can not order directly. Once there is a problem, the next day you purchase the goods through the bonded warehouse, which is a good way from the perspective of economics. But the key to doing this is that this component has less impact on production, and its value is much higher than the impact on production during night shifts. For parts that are frequently defective in the company's equipment or that are not in stock in the bonded warehouse, order and inventory should be made as needed.
5. Possibility of temporary emergency measures
There are many components in modern printing equipment that have the possibility of emergency. In the situation of increasing emphasis on timeliness, it is much more important to restore production than to repair faults. Under the theory of equipment maintenance to resume production, after a problem occurs, it can be temporarily treated by mechanical and electronic methods or by alternative means, so that the machine loses some less important auxiliary functions without affecting the normal production. If a component has the possibility of taking emergency measures in the event of a problem and it is determined that it will not cause a large impact within a certain period of time, you can temporarily not stock. Of course, the emergency measures are mainly to lose some less important auxiliary functions, which may only increase the labor of the workers. Such emergency measures can be adopted, but if there is any impact on safety, it is not recommended to use emergency measures.
There are two problems to be explained here. One is the printing equipment parts that we are talking about, and do not include printing consumables, such as rubber rollers, blankets, paper frame brake pads, and disassembling knives. The management of these consumables should be included. Daily management of materials. The second is to pay attention to the random parts of printing equipment. Modern rotary machine suppliers often provide a large number of spare parts at random. It should be said that the determination of these parts is determined by the manufacturer based on years of experience, and most of them are components that are prone to failure. Therefore, these parts must be managed in a focused manner. Once they are used, they need to be filled in time.