Printing Enterprise Cost Management

8. Correctly handle the relationship between maintenance costs and maintenance effectiveness

It is not desirable to simply reduce maintenance costs without considering maintenance effects. The printing industry has many imported equipment, imported spare parts are often overpriced, and domestic spare parts are often of low quality. How to obtain a comprehensive balance between the two is an important issue. Management issues. For key components, if necessary, we must use imported parts to improve the maintenance effect. For some domestic components that can pass quality control to meet quality requirements, we can use our own technical strength to independently develop the control quality, and we can also cooperate with related domestic manufacturers.

9. Implement equipment information management

We must pay attention to the collection and feedback of information throughout the entire process and conduct timely research and resolution. Equipment procurement process should also pay attention to using information from the maintenance department to support the accuracy of the decision. In addition, attention should also be paid to the collection of information from manufacturers to create a favorable environment for equipment procurement, maintenance, and renovation.
10. Classified management of equipment

According to the overall efficiency of the equipment, it is classified according to the degree of importance, and the key equipments are subject to key management. The main assessment factors are: the impact of failure, presence or absence of alternative equipment, starting conditions, difficulty of repair, impact on quality, original value, etc. By comprehensively evaluating the above factors, generally speaking, the key A-type equipment accounts for 10%, the general B-type accounts for 75%, and the minor C-type accounts for about 15%.

Third, the implementation of organizational measures and the effectiveness of evaluation

1, the effect of equipment management evaluation, the use of comprehensive analysis of economic and technological methods, mainly in the following indicators:

(1) Equipment availability

The ratio of the number of good equipment to the total number of equipment.

(2) Equipment failure rate

The ratio of downtime to production run time.

(3) Maintenance cost per unit product

The ratio of maintenance costs to total product output.

(4) Maintenance cost rate

The ratio of maintenance costs to total production costs.

2. The concept and methods of equipment management must be implemented through appropriate organizational management measures to achieve the intended purpose. Therefore, we must do the following aspects of the work.

(1) The equipment management should be placed at the center of the company's strategy, and strategic planning for equipment management should be done well. The printing industry is an industrial enterprise with the nature of processing services. It has the general characteristics of processing industrial production, but also has the marketing characteristics of the service industry. Equipment management has particularly important strategic significance.

(2) It is necessary to improve the level of equipment management, establish a responsibility system for equipment management and a sound assessment system. The head of the company must pay enough attention to the equipment management. Generally, it is the responsibility of a deputy factory-level leader, and a special director or deputy director is set up in each workshop and each department to take charge of the equipment management of the workshop and the department.

(3) Establish a plant-wide equipment management responsibility system, improve the assessment mechanism, and directly link the comprehensive effect with the salary income of personnel.

(4) Apply the whole process management concept to all aspects of equipment management, from maintenance and use to equipment ordering and equipment use.

(5) Establish an equipment management system with the whole process management, life cycle management, and preventive maintenance as the core, so that the equipment management department can change from routine maintenance to condition monitoring.

(6) Actively use its own scientific and technological power. The production companies have many years of practical experience in the experimental conditions, have the most say in the localization effect of some spare parts, and should actively use their own scientific and technological strength to carry out some development work. If some plastic parts, mechanical parts, etc. on the equipment can not be resolved in the country and the original product is expensive, it may be considered to carry out localization development independently, which can save a small amount of expenditure, and may even form a exportable product. product.

After the author's equipment management practices in recent years, using the above concepts and systems have achieved good results. Using the maintenance management approach centering on the preventive maintenance system, we reduced the number of full-time maintenance personnel by 70% in the case of a 100% increase in output value. The complete state of the equipment basically reached 100%, and the failure rate was close to 0, effectively ensuring the smooth progress of production. At the same time, maintenance costs have been declining year by year, especially after the introduction of new main equipments using the whole process management method. Maintenance costs have dropped drastically, maintenance costs for thousands of yuan have fallen by 50%, and more imported original materials have been used in production. The quality of products has been greatly improved and good economic benefits have been achieved. Some spare parts products independently developed by us save a lot of maintenance expenses. For example, the anilox roller saves 60%, the plastic gear saves 90%, the imager component maintains 99%, the printing roller repair saves 70%, and the deinking clutch saves. 95%, centralized ink supply system saves 50%, etc., greatly reducing equipment and maintenance costs.