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To do a good job in fault management and prevention of injection molding machines, it is necessary to understand the causes of injection molding machine faults, accumulate information and data on common and typical faults, conduct fault analysis, attach importance to the study of fault patterns and mechanisms, and strengthen daily maintenance, inspection, and pre repair. The deployment program of fault management has the following 8 aspects:
1. Carry out publicity and education work, so that operators and maintenance workers can conscientiously record, count, and analyze injection molding machine failures, and provide reasonable suggestions.
2. In close combination with the actual production of injection molding and the characteristics of injection molding machine conditions, divide the in use injection molding machines into three categories A, B, and C to determine the focus of fault management.
3. Use monitoring instruments to systematically monitor the key parts of the key injection molding machine, and promptly detect signs of faults and deterioration information.
Generally, injection molding machines also need to undergo daily inspection, patrol inspection, regular inspection (including accuracy inspection), and intact condition inspection through human senses and general testing tools, with a focus on mastering the technical status and abnormal phenomenon information of the parts, mechanisms, and components that are prone to faults. At the same time, inspection standards should be established to determine the boundaries between normal, abnormal, and faulty injection molding machines.
4. Conduct fault analysis and train injection molding machine maintenance workers to master fault analysis methods.
5. Fault records are the basic data for implementing fault management in injection molding machines, as well as the original basis for fault analysis and handling. The records must be complete and correct. After inspecting and repairing faults on site, injection molding machine maintenance workers should carefully fill out the "Injection Molding Machine Fault Repair Form", and workshop mechanics should conduct monthly statistical analysis and submit it to the injection molding machine management supervisor.
6. Workshop injection molding machine maintenance personnel should collect "fault repair orders" and maintenance records on a monthly basis, in addition to daily monitoring of fault situations. By statistics, organization, and analysis of fault data, the frequency and average interval between failures of various injection molding machines are calculated. The fault dynamics and key causes of a single injection molding machine are analyzed to identify the occurrence patterns of faults, in order to highlight key measures and take countermeasures. The fault information is organized and analyzed and fed back to the planning department for arranging preventive repair or improvement measures. It can also be used to modify the interval between regular inspections The basis for checking the content and standards.
Based on the statistical data, statistical analysis charts can be drawn, such as the dynamic statistical analysis table for single injection molding machine faults, which is an effective method for maintenance teams to visually manage faults and other issues. It not only facilitates management personnel and maintenance workers to timely grasp the situation of various types of injection molding machine faults, but also has clear goals when determining maintenance strategies.
7. Through the daily patrol inspection and status inspection of injection molding machine maintenance workers, the status information and fault signs obtained, as well as relevant records and analysis data, are promptly arranged by the workshop injection molding machine maintenance personnel or repair team leader to address the existing problems of various types of injection molding machines, fully utilizing production gap time or holidays, and achieving prevention first to control and reduce the occurrence of faults. For certain fault symptoms and hidden dangers that cannot be borne by daily maintenance, feedback will be given to the planning department to arrange for planned repairs.
8. Develop a fault information management flowchart.
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