400 820 5059
150-2122-3752
400 820 5059
150-2122-3752
According to the law of market competition, what exists is reasonable, while what is unreasonable will gradually be eliminated by the market. Therefore, the long-term high maintenance costs of a large number of air compressors in the market inevitably have their rationality and objective reasons for existence, which requires practical analysis in combination with industry development and equipment procurement management concepts. Below, Sikeluo editor will introduce to you the methods and measures to reduce the maintenance costs of air compressors.
1. Strengthen equipment updates and technological upgrades
Modern technology is developing rapidly, and the updating of air compressor equipment and the application of new technologies have a significant effect on improving the operational reliability of equipment and reducing maintenance costs. At present, many companies still have air compressor equipment from over a decade ago, with outdated technology, low production efficiency, cumbersome operation, and expensive spare parts. Some of these old equipment must be phased out, while others can undergo technological upgrades, which will significantly reduce maintenance and spare parts costs.
2. Ensure the quality of spare parts and components
The quality of spare parts directly determines the service life of the machine, the reliability of the equipment, and the scope of maintenance. High quality spare parts can not only help maintenance personnel solve faults in a timely manner, but also improve the reliability of the entire system, extend the service life of related components, and improve the overall performance of the equipment. On the contrary, low-quality spare parts not only fail to solve the problems that occur in the equipment, but also cause new failures, reduce the reliability of the system, and even lead to major disasters. For example, if the quality of the filter element and lubricating oil we often use is not good, it can cause blockage, overheating, wear and other faults. Not only does it have a short service life, but it can also cause the equipment to stop when it should not be stopped, which is prone to production accidents.
3. Strengthen the management of replacement spare parts during maintenance
In the troubleshooting of air compressors, especially when users perform maintenance and upkeep themselves, it is common to encounter situations where one spare part is damaged but the other is replaced, or the equipment needs to be adjusted but the spare part is replaced, resulting in waste. The reason for this phenomenon is the lack of corresponding supervision mechanisms in spare parts management, and maintenance workers are not responsible for the quality of the replaced spare parts. This requires establishing a mechanism to make each repairman responsible for the spare parts they replace, ensuring that the replaced parts are indeed damaged. The replacement of spare parts shall be reviewed by an appraisal team composed of relevant personnel. If no damaged spare parts are found and replaced, the replacement person shall be punished. The appraisal team is responsible for the appraisal results and will strictly punish those who intentionally conduct erroneous appraisal for personal gain and fraud, so as to solve the problem of easy replacement of spare parts.
There is still a problem in practical operation, which is that maintenance personnel are unable to determine the degree of damage to spare parts. For parts that are suspected to have faults during maintenance, the repairman can use replacement methods to eliminate them. If the part is normal, it must be reinstalled and new spare parts are not allowed to be used. Accurate records should be kept of replaced spare parts, and supervision of spare parts should be strengthened. Usage records should be kept, and the average service life should be calculated to reduce the inventory of spare parts. Timely procurement should be made before the spare parts are damaged to prevent insufficient use.
4. The sense of responsibility of maintenance personnel
With the extension of the service life of air compressors, equipment aging is an irreversible fact. The replacement of aging spare parts can be carried out at any time, and the replacement of spare parts is largely controlled by maintenance workers, with many factors that are artificially controlled. Maintenance workers need to understand the usage of spare parts, roughly estimate the time of damage, and prepare spare parts for timely replacement before they are damaged. This can reduce equipment maintenance time, avoid spare parts waste, and lower warehouse inventory. This requires maintenance workers to have a sense of ownership and strong sense of responsibility. Enterprise leaders must first attach importance to maintenance workers, making them feel that if they do not do it seriously, they will be sorry to the company.
5. Strengthen the maintenance of available spare parts
Many of the damaged spare parts that have been replaced can still be reused after repair, but many maintenance workers are unwilling to repair the damaged spare parts for the following reasons:
(1) Lack of necessary maintenance tools. The original maintenance concept believed that mechanical repairmen only needed hammers, screwdrivers, and a wrench, while electrical repairmen's tools were a multimeter, a pointed pliers, a screwdriver, and a roll of insulating tape. Such simple tools were impossible to repair damaged spare parts. Therefore, enterprises need to be equipped with necessary maintenance tools.
(2) Lack of corresponding incentive mechanisms. The original management philosophy believed that the utilization of waste parts by maintenance workers during working hours was within the scope of their work, and not repairing it was dereliction of duty. The maintenance workers worked hard to repair a expensive spare part, putting in a lot of effort and labor, but did not receive any encouragement or reward. The labor they put in was not proportional to their income, so they lost their enthusiasm for the reuse of waste parts. Enterprises should take corresponding reward measures, based on the price, reuse value, reliability, etc. of spare parts, and reward personnel who repair spare parts at a certain ratio of spare parts price, and link it with evaluation to stimulate the enthusiasm of maintenance personnel for the reuse of waste parts.
6. Strengthen the management of spare parts types
Some types of spare parts in the enterprise spare parts warehouse are insufficient, while others have a backlog of types. It is necessary to establish an upper and lower limit ledger for commonly used spare parts, ensuring that they do not exceed the upper limit and are not lower than the lower limit. While ensuring the normal operation of the equipment, it not only ensures the normal use requirements of the equipment, but also does not cause a backlog of spare parts.
7. Extend the service life of components
Encourage technological breakthroughs to extend the service life of vulnerable components. Many vulnerable components can extend their service life through technological improvements, which can also save a lot of maintenance costs.
Many times, air compressor manufacturers test their products for tens of thousands of hours, but they break down shortly after receiving them from users. Users complain about poor product quality - this is often caused by the unreasonable use of user operators.
Many operators claim to understand technology and are often lazy to learn operating manuals and regulations for newly introduced air compressor equipment, believing that they are all screw compressors with little difference. In fact, air compressors have different requirements for operation, maintenance time, and techniques due to their different designs, specifications, and operating conditions. Seemingly right but not paying attention to details is often the root cause of faults.
8. Adhere to the daily, weekly, and monthly maintenance system
Establish strict maintenance systems to encourage operators to strictly follow regulations, promptly address potential faults, eliminate them in the bud, and extend the service life of spare parts. This is particularly important for the lubrication components and electrical components of the bracket.
Scrcompressor is a high-tech enterprise with independent intellectual property rights, focusing on the research and development, manufacturing, sales, and service of screw air compressors. The company has an air compressor manufacturing base of 80000 square meters, with a product family mainly consisting of micro oil, dry oil-free, low-pressure, engineering, mobile, permanent magnet variable frequency, and a full range of air compressors for buses and locomotives. The company has four modern assembly lines for complete machines and precision machining equipment imported from Europe and America. By using the ERP management platform, it ensures the operation and quality process control of the entire industry chain, and complies with the ISO9001-2008 quality management system. After years of development, it has been awarded titles such as "Famous Trademark, Famous Brand Product, National Energy saving Product, and AAA Contract Integrity".
