Organization of a vehicle maintenance area. Organization of work at the maintenance and repair site of a motor transport enterprise. The most important element of protecting workers from exposure to dangerous and harmful factors is compliance with the rules

Introduction

1. Technological part

1.3 Determination of the annual labor intensity of work

1.4 Determination of the number of production workers

1.5 Determination of the number of site posts

1.7 Determination of production areas of the site

1.8 Planning solutions for buildings

2. Organizational part

3.1 Compliance with safety requirements when performing work in the area

4. Energy saving in the area

4.2 Measures to save thermal energy

Conclusion

Literature

Introduction

Automotive passenger transport is the main mode of transport for short and medium distance travel. Road transport represents one of the largest industries National economy with complex and diverse equipment and technology, as well as a specific organization and management system.

For normal operation road transport and its further development, it is necessary to systematically update the vehicle fleet and maintain it in good technical condition. Ensuring the required number of rolling stock can be carried out in two directions:

purchasing new cars;

accumulation of the fleet due to machine repairs.

Car repair is an objective necessity, which is due to technical and economic reasons.

Firstly, the national economy's need for cars is partially satisfied by using refurbished cars.

Secondly, repairs ensure the continued use of those car elements that are not completely worn out. As a result, a significant amount of previous labor spent on producing these parts is retained.

Thirdly, repairs help to save materials used for the production of new cars.

The technical perfection of cars in terms of their durability and labor-intensive repairs should be assessed not from the point of view of the possibility of correcting and restoring worn parts in the conditions of repair enterprises, but from the point of view of the need to create cars that require only low-labor disassembly and assembly work during repair, associated with the change of interchangeable quickly wearing parts. parts and assemblies.

An important element of the optimal organization of repairs is the creation of the necessary technical base, which predetermines the introduction of progressive forms of labor organization, increasing the level of mechanization of work, equipment productivity, and reducing labor costs and funds.

The purpose of the course project is to design an electrical department, determine the labor intensity of work, the number of workers, select equipment, and develop a technological map.

1. Technological part

1.1 Selection of initial data for design

The initial data for the technological calculation are selected from the design assignment and from the regulatory literature.

Initial data from the design assignment:

The number of population in the serviced area is P = 9000 people;

Number of cars per 1000 inhabitants - Audi. =225 units;

The average annual mileage of a car is LГ = 14,000 km;

The standard specific labor intensity of maintenance and repairs per 1000 km is tn maintenance and repairs = 2.43 man-hours/1000 km;

Coefficient taking into account the number of clients using the services of a car service organization - kkp = 0.81

The climate is moderately warm.

Initial data from normative literature:

Days of vehicle downtime for maintenance and repair, dTO AND TR, days/1000 km;

Labor intensity standard for diagnostic work, man-hours;

Maintenance frequency standard, km;

Mileage between repairs, km;

Number of days of vehicle downtime for major repairs, recreation center, days.

1.2 Determining the number of cars serviced in a given area

The annual number of cars serviced in a given area is determined by the formula

car maintenance equipment

where P is the number of residents in the serviced area;

Audi. - the number of cars per 1000 inhabitants according to traffic police data;

Kkp - coefficient taking into account the number of clients using PAS services, which is taken equal to 0.75-0.90;

1.3 Determination of the annual labor intensity of work

The annual volume of maintenance and repair work for urban motor vehicles is determined by the formula

Where LГ is the annual mileage of the car;

Asto - number of cars serviced;

tTO,TR - specific labor intensity of maintenance and repair per 100 km, person hours/1000;

The specific labor intensity of maintenance and repairs per 100 km, person hours/1000 is determined by the formula

Where tnTO, TR - standard specific labor intensity of maintenance and repair per 1000 km, person-hours;

K1 - coefficient taking into account the number of work posts (up to 5-1.05, from 6 to 10-1.0, from 16 to 26-0.9, from 26 to 35-0.85, over 35-08);

K3 - coefficient taking into account the climate zone

tTO,TR = 2.4310.9 = 2.19 person-hour

50% of the work is carried out at the post, repair of components, systems and assemblies is 14.9%

TTO,TR= 502820.50.147= 2891 man-hours

1.4 Calculation of the number of production workers

For the maintenance and repair zones, in which work is performed directly on the vehicle, the technologically required number of RT workers, people. determined by the formula

where Fm is the annual fund of time at the workplace, hours (from the production calendar);

kn - coefficient of uneven loading of posts,

Coefficient of use of working time at the post (Table 9).

We accept 2 people.

1.5 Calculation of the number of posts in the TO-2 zone

The number of posts n is determined by the formula

where TN is the annual volume of guard work, man-hours,

Coefficient of uneven arrival of cars at the post, (=1.15),

Рср - average number of workers at one post, (Table 8),

Фп - annual fund of working time of the post, person-hours,

Post working time utilization rate (= 0.94-0.95)

accept 1

1.6 Selection of technological equipment, technological and organizational equipment

Table 11 - Technological equipment, technological and organizational equipment

Name		Dimensions in plan, mm	Footprint,	Notes

Pneumatic impact wrench for wheel nuts
Hydraulic lift
Engine removal tool
Tool for removing gearbox
Installation for removing oil and filling from the engine system
Installation for filling and removing coolant
Installation for removing front suspension springs
Trolley for transporting units
Tool trolley	Unior Europlus_920Plus1
Metalworking workbench
A set of keys
Exhaust gas removal device	Vega 3515/100 UEH
Installation for removing the rear axle gearbox
Wash basin
Sectional shelving
Installation for replacing steering mechanisms

Oil drain container (polyethylene)

1.7 Calculation of the production area of the TR site

The area of the plot is determined by the formula

F3 = fa xs kpl,

Where kpl is the coefficient of density of equipment placement and placement of posts, [p. 54.14],

xz - coefficient,

fa - the area occupied by a car in terms of m2.

F3 = 9.6 6.52= 124.8 m2

2. Organizational part

Technological map for removing a gearbox from a passenger car

Name	Standard time	Tools	Technical conditions and penalties
Remove the intercooler and engine cover
Remove the battery
Disconnect the mass air flow sensor connector
Remove the air filter hose and loosen the clamp bolt
Remove the clamp and then top cover air filter
Unscrew to install the bolt and then remove air filter assembled
Remove the four bolts and then remove the battery shelf
Remove the negative terminal from the gearbox
Disconnect the vehicle speed sensor connector and turn off the light reverse
Remove the control cable assembly by removing the locking pins and clamps.
Remove the coaxial slave cylinder tube
Remove the four transmission top mounting bolts
Support engine and gearbox		Using special equipment
Unscrew the bolts and then remove the gearbox insulating mount
Remove the front wheels
Raise the vehicle
Unscrew the steering column connecting bolt
Remove the vehicle's lower protection
Drain the power steering system fluid through the return pipe
Disconnect the power steering pressure hose from the pump.
Drain transmission oil gearbox through the drain hole
Disconnect the lower arm, ball joint tie rod end, anti-roll bar link from the front steering knuckle
Unscrew the roller support mounting bolt
Remove the mounting bolts from the subframe, support the subframe		Using a jack
Disconnect the drive shafts from the gearbox
Disconnect the connector from the starter and remove the starter
Remove the gearbox cover			For four-wheel drive vehicle remove the gearbox housing assembly
Unscrew the mounting bolts of the lower part of the gearbox and the left side cover and remove the gearbox assembly while supporting it		Using a jack

3. Labor protection and environment

3.1 Compliance with safety requirements when performing work in the department

General safety requirements include checking the technical readiness of the machine, its start-up, inspection after completion of work and troubleshooting. Workplace must be comfortable and provide a good overview of the work front, equipped with fences, protective and safety devices and devices.

Increased safety is achieved by using safety devices.

Before being allowed to work, mechanics and their assistants, against signature, receive instructions that also contain safety requirements. Every year in persons servicing machines, test knowledge within the scope of the production instructions. The results of the knowledge test are drawn up and entered into the certification and knowledge test journal. Before starting work, you must submit a warning notice. sound signal. Do not start work in insufficient lighting.

Operation must be stopped if safety devices are damaged and if emergency situations. Upon completion of work, all flammable and lubricating materials must be returned to the warehouse. Switch in front of the main power cable power plant with an electric drive must be turned off and locked. In the event of an accident or accident, it is necessary to stop the power plant until an administration representative arrives. Failure to follow safety regulations can result in work-related injuries.

Modern machines and equipment are equipped with means to protect workers from vibration, shock, industrial noise, and dust.

To prevent electric shock in the lighting or control network, use, if possible, electricity voltage up to 36 V; insulate and fence electrical equipment and live wires; install protective equipment that turns off electrical equipment in case of dangerous loads in the electrical circuit; ground electrical equipment.

3.2 Compliance with industrial hygiene requirements

Industrial sanitation is a system of organizational measures and technical means, preventing or reducing the impact of harmful production factors on workers. The main dangerous and harmful production factors are: increased dust and gas contamination of the air in the working area; increased or decreased air temperature in the working area; increased or decreased humidity and air mobility in work area; increased noise level; increased level of vibration; increased level of various electromagnetic radiation; lack or lack of natural light; insufficient illumination of the work area and others.

Dangerous and harmful production factors:

Physical;

Chemical;

Biological;

Psychophysiological.

Boundaries of industrial sanitation:

Improvement of the air environment and normalization of microclimate parameters in the work area;

Protection of workers from noise, vibration, electromagnetic radiation, etc.;

Ensuring the required standards of natural and artificial lighting;

Maintaining the organization’s territory, main production and auxiliary premises in accordance with sanitary requirements.

The industrial microclimate is one of the main factors influencing human performance and health. Meteorological factors greatly influence human life, well-being and health. An unfavorable combination of factors leads to disruption of thermoregulation.

In accordance with GOST 12.0.003-74 “SSBT. Dangerous and harmful production factors. Classification "increased dust and gas contamination of the air in the working area refers to physically dangerous and harmful production factors.

Many substances entering the body lead to acute and chronic poisoning. The ability of a substance to cause harmful effects on the functioning of the body is called toxicity.

3.3 Ensuring environmental protection

Road transport is one of the powerful sources of environmental pollution. The direct negative impact of cars on the environment is associated with emissions of harmful substances into the atmosphere. The indirect impact of road transport on the environment is due to the fact that car roads, parking lots, service enterprises occupy an ever larger and daily increasing area necessary for human life.

Environmental protection work at each AP should include the following basic activities:

Training of emergency personnel and drivers in the basics of environmental safety;

Improving the technical condition of rolling stock produced on the line, saving fuel, reducing empty mileage of vehicles, rational organization of traffic;

Organization of warm parking lots, electric heating of cars and other measures to improve the state of the environment;

Ensuring the serviceability of vehicles, proper adjustment of engine operation;

Elimination of leakage of fuel, oil, antifreeze in the parking lot;

Cleaning up leaks of operating materials, backfilling with sand or sawdust;

Collection of used oils and other liquids and delivery to collection points;

Periodic checking for smoke and prohibiting the release of vehicles onto the line with high smoke gases;

Organization and support effective cleaning wastewater from household, industrial and storm water through treatment facilities, the introduction of recycled water supply at the AP;

Systematic monitoring of the condition of vehicle components and assemblies in order to reduce noise;

If there is an operating boiler house on the territory of the accident, it is necessary to provide measures to reduce air pollution by harmful emissions (smoke, soot, gases), in the future - the liquidation of the boiler house on the territory of the anti-terrorist operation and the transition to central heating.

The territory, production, auxiliary, sanitary premises and areas for storing cars must comply with current sanitary standards and rules. Garbage, industrial waste, etc. must be promptly removed to specially designated areas. Enterprise areas must be equipped with drainage systems. Where acids, alkalis and petroleum products are used, floors must be resistant to these substances and not absorb them.

Storage facilities and Maintenance vehicles, where a rapid increase in the concentration of toxic substances in the air is possible, must be equipped with an automatic monitoring system for the state of the air in the working area and alarms.

The organization must be equipped with drinking and industrial water supply, as well as industrial sewerage in accordance with the standards.

4. Energy saving in the electromechanical section

4.1 Measures to save energy

The main ways to reduce electricity losses in industry are:

Rational construction of the power supply system;

Laying networks in polyurethane foam insulation;

Wiping a light bulb from dust;

Do not leave electrical appliances in standby mode;

Painting walls and ceilings white;

Maximizing natural light;

Use of solar panels;

Replacing incandescent lamps with energy-saving lamps;

Transfer of loads from the peak hours of the power system to other hours;

Application of 2 tariff meters;

Reducing the growth of energy tariffs;

Development of a methodology for determining specific energy consumption standards.

4.2 Measures to save thermal energy

The successful application of energy-saving technology largely determines the standards of technological and construction design of buildings and, in particular, the requirements for the parameters of internal air, specific heat, moisture, steam, and gas emissions.

Significant fuel saving reserves lie in rational architectural and construction design of new public buildings. Savings can be achieved:

Appropriate choice of shape and orientation of buildings; - space-planning solutions; - selection of heat-protective qualities of external fences; - selection of walls and window sizes differentiated by cardinal directions.

Careful installation of systems, thermal insulation, timely commissioning, adherence to deadlines and scope of work for maintenance and repair of systems and individual elements- important reserves for saving fuel and energy resources.

To radically change the situation with the use of heat for heating and hot water supply of buildings, we need to implement a whole range of legislative measures that determine the procedure for the design, construction and operation of structures for various purposes.

The requirements for design solutions for buildings that ensure reduced energy consumption must be clearly formulated; methods for rationing the use of energy resources have been revised. The goals of saving heat for heating buildings should also be reflected in the relevant plans for the social and economic development of the republic.

Equipping heat consumers with means of monitoring and regulating consumption allows reducing energy costs by no less than 10-14%. And when taking into account changes in wind speed - up to 20%. In addition, the use of façade-by-facade control systems for heat supply for heating makes it possible to reduce heat consumption by 5-7%. By automatically regulating the operation of central and individual heating points and reducing or eliminating network water losses, savings of up to 10% are achieved.

With the help of regulators and means of operational temperature control in heated rooms, you can stably maintain a comfortable mode while simultaneously reducing the temperature by 1-2C. This makes it possible to reduce up to 10% of the fuel spent on heating. By intensifying the heat transfer of heating devices using fans, a reduction in thermal energy consumption by up to 20% is achieved.

Thermal insulation of the ceiling with fiberglass mats can reduce heat loss by 69%. Cost recovery for additional device thermal insulation - less than 3 years. During the heating season, savings were achieved compared to standard solutions - in the range of 14-71%.

The use of low-density concrete with fillers such as perlite or other lightweight materials for the manufacture of building envelopes allows the thermal resistance of organizations to be increased by 4-8 times.

The main directions of work on saving thermal energy in heat supply systems of buildings are:

Development and application in planning and production of technically and economically sound progressive norms for thermal energy consumption to implement saving modes and their most effective use;

Organization of effective accounting of heat supply and consumption;

Optimization of operating modes of heating networks with the development and implementation of adjustment measures;

Development and implementation of organizational and technical measures to eliminate unproductive heat losses and leaks in networks.

Conclusion

In this course project the following tasks were solved:

Selected source data;

The number of cars serviced in a given area is determined;

The annual labor intensity of the work was determined;

The number of production workers has been determined

The number of site posts has been determined;

The selection of technological equipment, technological and organizational equipment was carried out;

The production area of the designed diagnostic site has been determined;

The maintenance area has been laid out

List of sources used

Standards

1 GOST 2.105-95. ESKD. General requirements for text documents.

2 GOST 21.204-93 Conditional graphic symbols and images of elements of master plans and transport structures.

3 TKP 248-2010 (02190). Automotive maintenance and repair Vehicle. Norms and rules of conduct.

Literature

Main literature

Internet sources.

5 Kovalenko N.A. Technical operation of cars: textbook / N.A. Kovalenko, V.PLobakh, N.V. Veprintsev. - Mn., 2008.

6 Kovalenko N.A. Technical operation of vehicles. Course and diploma design: textbook / N.A. Kovalenko, ed. ON THE. Kovalenko - Mn., 2011.

7 Lokhnitsky I.A. Energy saving / I.A. Lokhnitsky. - Mn., 2004.

9 Guidelines for course design By technical operation cars.

10 Design of automobile transport enterprises: textbook/M.M. Bolbas; edited by MM. Bolbasa. - Mn., 2004.

11 Sokol T.S. Occupational safety: textbook/T.S. Falcon; edited by N.V. Ovchinnikova. - Mn., 2005.

12 Sukhanov B.N. Maintenance and repair of automobiles: a manual for diploma design / B.N. Sukhanov, I.O. Borzykh, Yu.F. Bedarev. - M., 1991.

additional literature

13 Turevsky I.S. Occupational safety in road transport: textbook/I.S. Turevsky. - M., 2009.

14 Novochikhina L.I. Handbook of technical drawing/L.I. Novichikhin. - Mn., 2004.

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maximum)

tn – time for setting up and removing the car from the post, we assume – 3 minutes.

The number of lines TO-1 and TO-2 is determined by the formula:

(2.43)

2.9 Determination of the number of posts in TR zones

The number of TR posts is determined by the formula:

, (2.44)

where TTOpost is the annual volume of guard work, for trucks the labor intensity of guard work is taken = 44% of the annual volume of technical work (chapter 3) TTR = 5704512∙11.0/1000 = 62749.6 people∙h;

Kn – coefficient that takes into account the fulfillment of the volume during the busiest shift, we take Kn = 1.12 (Table 3.1);

Др – number of working days of the zone in a year, we accept – 255 days;

tcm – shift duration, tc = 8 hours;

Рср – number of workers at the post, people; for KamAZ-5320 and KamAZ-54118: Рср = 1.5 people (Table 3.3);

C – number of shifts, assume 1 shift;

η – coefficient of use of working time of the post, η = 0.93 (Table 3.2).

Number of TR posts for KamAZ-5320 and KamAZ-54118:

We accept 11 posts.

2.10 Distribution of workers among posts in TO-2 zone

The operating mode of zones TO-2 and TO-1 is as follows:

Zone TO-2 operates on the first shift, the duration of the zone is 9 hours, the number of work stations is 2;

Zone TO-1 operates on the second shift, the duration of the zone is 8 hours, production lines are located on the same lines as TO-2.

Table 2.14-Distribution of workers among posts in TO-2 zone

Post number	Number of executors in office	Speciality	Qualification	Serviced units and systems
1		Repair mechanics cars		Clutch, gearbox, driveline and rear axle
	2	Same		Front axle and steering
	4	Repair mechanics cars		Power system, engine
2	2	Car repair mechanics	III	Body, cabin
	2	Same	II	tires
		Repair mechanics cars
	2	electric battery workers	IV	Electrical equipment and batteries

2.11 Selection of technological equipment for the engine section

We select technological equipment for the engine section in accordance with recommendations and according to catalogs of technological equipment for vehicle maintenance and repair.

Table-2.15 Technological equipment for the motor section

Pos	Name	Qty	Note
1	Tool cabinets for machine operators	2
2	Screw-cutting lathes	2
3	Vertical drilling machine	1
4	Bench workbenches	3
5	Bench vice	3
6	Bench Drilling Machine	1
7	Manual press	1
8	Valve Chamfer Grinding Machine	1
9	Engine repair stands	2
10	Surface plate	1
11	Shelving for parts	2
12	Hydraulic Press	1
13	Chest for cleaning materials	1
14	Bath for washing parts	2
15	Tool sharpening machine	1
16	Overhead crane	1
17	Engine platform	1

3 Organizational part

3.1 Organization of maintenance and repair production by management at the site

The organizational and production structure of the engineering and technical service (ITS) is understood as an ordered set of production units that determines their number, size, specialization, relationship, methods and forms of interaction.

The production structure of a motor transport enterprise is a form of organization of the production process and is reflected in the composition and number of workshops and services, their layout; in the composition and number of jobs inside the workshops.

In general, the organizational and production structure of the ITS, which includes functional groups of departments to perform the specified tasks and manage the process of their implementation, is shown in Figure 3.1.

The engineering and technical service includes the following production areas and complexes:

Maintenance and diagnostics complex (TOD), which unites performers and teams of EO, TO-1, TO-2, and diagnostics;

The TR complex, which combines units that carry out repair work directly on the vehicle (guard units);

A complex of repair areas (RU), which brings together departments and performers engaged in the restoration of the working capital of units, components and parts.

A number of works are performed directly on the car and in workshops (electrical, tinsmithing, welding, painting, etc.). The assignment of these units to the TR or RU complex is made taking into account the predominant (in terms of labor intensity) type of work.

ITS includes the following subsystems (divisions, departments, workshops, areas):

ITS management represented by the chief engineer responsible for the technical condition of vehicles, their road and environmental safety;

Group (center, department) for production management of vehicle maintenance and repair;

Technical department, where planning solutions for the reconstruction and technical re-equipment of the production and technical base are developed, the selection and ordering of technological equipment, and the development of technological maps are carried out; occupational health and safety measures are developed and implemented, the causes of occupational injuries are studied and measures are taken to eliminate them; technical training is carried out to train personnel and improve the qualifications of personnel; technical standards and instructions are drawn up, non-standard equipment, fixtures and fittings are designed;

The department of the chief mechanic, which carries out the maintenance of buildings, structures, power and sanitary facilities in a technically sound condition, as well as the installation, maintenance and repair of technological equipment, tooling and control over their correct use; production of non-standard equipment;

The logistics department, which ensures logistics, preparation of supply requests and effective organization of warehouse operations. One of the important conditions for improving the use of rolling stock and increasing its technical readiness is the timely provision of ATP with fuel, spare parts, tires, garage and repair equipment. The accurate implementation of production indicators, the rhythmic operation of the enterprise, and increased labor productivity depend on the rational use of material and technical means. Economical use of resources and reduction of their consumption reduces the cost of transportation.

The logistics department (MTO) must provide production with the necessary material resources and monitor their consumption and use.

The logistics plan consists of separate calculation tables classified by type of materials:

The need for fuel, lubricants and operating materials, tires, spare parts;

Demand for fuel for technological purposes and electricity;

Demand for rolling stock and equipment.

The purpose of this type of planning is to save material resources due to various factors, as well as control the consumption of materials.

The logistics department (MTS) is tasked with determining the need for various types of raw materials, equipment, etc.

Managing the consumption of operating materials in the ATP, aimed at the efficient use of rolling stock, includes planning the consumption of materials according to standards, by nomenclature and quantity, by actual costs, in monetary terms; receiving, storing and issuing materials; operational and current flow control (Figure 3.1).

Figure 3.1 – Scheme for managing the consumption of operating materials

The share of fuel in the total cost of transportation is 15-20%. Therefore, saving fuel and lubricants (LCM) is important as a factor not only in reducing the cost of road transport, but also in reducing energy resources.

In practice, a number of measures are provided aimed at the economical consumption of fuel and materials during their transportation from warehouses, during storage, distribution and during the operation of the vehicle.

TCM is issued to the driver using coupons based on the waybill. The amount of fuel and oil is included in the waybill. The issuance of TCM for maintenance and repair is carried out on the basis of the requirement. For the primary accounting of fuel and materials, the enterprise maintains a “Fuel and Materials Accounting Book”.

The Operations Department is prohibited from accepting waybills that do not contain information about the issuance of TCM. After the waybills are processed in the operation department, they are submitted to the FCM accounting group, where actual and normal fuel consumption for each vehicle is specifically recorded. The fuel metering technician fills out a registration card for each vehicle and the driver’s personal account, which records the transport work performed, the number of trips, and fuel consumption according to the norm and actual. Fuel consumption is monitored for the vehicle and driver in liters, and for the vehicle as a whole – in kilograms.

Spare parts account for about 70% of the range of products and materials consumed by automobiles. Car tires and batteries are not included in the range of spare parts, so they are taken into account and distributed separately.

The list of materials that are used to meet the economic needs of ATP is quite large. Among them are cutting and measuring tools, electronic and technical materials, and workwear. Logistics workers who supply the enterprise need to order them in advance and in the right quantities, receive them on time, properly distribute and store them. The enterprise's need for spare parts depends on a large number of factors, which can be characterized by the following groups: structural, operational, technological and organizational. The technical control department, which monitors the completeness and quality of work performed by all production departments, controls the technical condition of the rolling stock when it is received and released onto the line. Production preparation complex that carries out production preparation, i.e. completing the working stock of spare parts and materials, storing and regulating inventories, delivering units, components and parts to work stations, washing and completing the repair stock, providing workers with tools, as well as driving vehicles in maintenance, repair and waiting areas. The organization of production of maintenance and repair of vehicles in 121-PCh GU PTC FPS in the Sverdlovsk region is carried out using the aggregate-precinct method. Which consists in the fact that all maintenance and repair work on rolling stock is distributed among production areas responsible for performing all maintenance and repair work on one or more units (units, mechanisms, systems) for all vehicles in the fleet (Figure 3.2).

Figure 3.2 – Structure of the engineering and technical service when organizing the production of maintenance and repair according to the aggregate-sectional method

3.2 Organization of the technological process for repairing units

Routine repair of units and components is carried out in cases where it is impossible to restore their operational performance through adjustment work. The general flow diagram of the current repair process is shown in Figure 3.3.

Figure 3.3– Scheme of the technological process of current repair of units

For successful and high-quality repairs and in order to reduce labor costs, current repairs of units and components are carried out in specialized workshops equipped with modern and highly efficient equipment, lifting and transport mechanisms, instruments, fixtures and tools. All work on routine repairs of units, components and parts must be carried out in strict accordance with technical specifications.

The quality of the repair depends on the level of completion of all work, from washing and disassembling to testing the assembled unit and assembly.

One of the main conditions for high-quality repairs is careful and correct disassembly, ensuring the safety and completeness of non-depersonalized parts.

Units and components coming for disassembly must be cleaned of dirt and washed.

Each disassembly operation must be performed with tools and devices provided for by the technological process, on special stands and workbenches.

After disassembling the parts of units and components, it is recommended to wash them in a washing unit (small parts are placed in mesh baskets) with special washing solutions at a temperature of 60-80 ° C and in a bath for washing parts coldly using solvents (kerosene, diesel fuel).

Cleaning parts from carbon deposits, scale, dirt, etc. It is produced mechanically (with metal brushes, scrapers), or by physical and chemical action on the surface of parts.

The oil channels are washed with kerosene, cleaned with brushes and blown with compressed air.

Drying of parts after washing is carried out by blowing with compressed air.

After washing and cleaning, the parts are inspected and sorted. Inspection of parts is carried out to determine the technical condition and sort them in accordance with the technical conditions into those that are suitable, require restoration and are subject to replacement.

Suitable parts include parts whose wear is within acceptable limits; parts whose wear is higher than permissible, but can be used after restoration. Parts that are unsuitable for use due to complete wear or serious defects are sorted into scrap.

When inspecting and sorting, it is necessary not to depersonalize mating parts suitable for use.

Inspection of parts is carried out by external inspection to identify obvious defects and with the help of special devices, fixtures and tools that make it possible to detect hidden defects.

Before assembly, units and assemblies are equipped with parts that have undergone the troubleshooting process and are found suitable for further use, as well as restored or new.

Parts arriving for assembly must be clean and dry; traces of corrosion and scale are not allowed. The anti-corrosion coating must be removed immediately before installation on the engine.

The following are not allowed for assembly:

Custom size fasteners;

Nuts, bolts, studs with clogged or stripped threads;

Bolts and nuts with worn edges, screws with clogged or torn heads;

Used lock washers and plates, cotter pins, tie wire.

Parts that are coupled with transitional and press fits must be assembled using special mandrels and devices.

Rolling bearings must be pressed onto shafts and pressed into seats using special mandrels that ensure the transmission of force when pressed onto the shaft through the inner ring, and when pressed into the seat - through the outer ring of the bearing.

Before pressing parts, the seating surfaces are thoroughly wiped, and the working surface of the oil seals and the seating surfaces of the shaft and seat are lubricated with a thin layer of lubricant CIATIM-201 GOST 6257-74.

Installation of oil seals should only be done using special mandrels; and install the oil seal on the shaft using mandrels that have a smooth lead-in and surface cleanliness not lower than the cleanliness of the shaft.

Before pressing in, the oil seal with rubber cuffs is lubricated with grease to avoid damage; the seating surface of the part under the oil seal is lubricated with a thin layer of red lead, whitewash or undiluted hydrovarnish to ensure tightness.

During assembly, gaskets must be clean, smooth and fit tightly to the mating surfaces; Protrusion of gaskets beyond the perimeter of mating surfaces is not allowed.

For ease of assembly, cardboard gaskets can be installed using grease.

It is not allowed to cover oil, water and air channels with gaskets. The specified tightening torque of threaded connections is ensured by using torque wrenches. All bolted connections are tightened in two steps (preliminary and final tightening) evenly around the perimeter (unless there are special instructions on the tightening order).

Assembly work must be carried out in accordance with the technical specifications for assembly. An example of performing assembly operations is given in the technological map for engine assembly (Appendix A).

After assembly, each unit must undergo a performance test under load, a tightness test of connections, and compliance of operational parameters with the manufacturer’s specifications.

For running-in and testing of units, special stands should be used. The quality of parts running-in is assessed based on the results of a control inspection.

During the testing of units or components or after it, it is necessary to carry out adjustment and control work in order to bring it to an optimal operating mode, achieve the required structural parameters (gaps in mating parts, center-to-center distances, deflections, displacements, linear dimensions, condition of surfaces of mating parts, etc.). d.).

Quality control of current repairs of a unit or assembly is carried out by the person responsible for repairs and a representative of the technical control department. During the acceptance process, attention is paid to the compliance of the assembly with the technical conditions and output parameters of the unit specified in the technical specifications of the manufacturer.

3.3 Lighting calculation

In a room with an area of 324 m2, it is necessary to create an illumination of E = 200 lux. We choose PVLM type lamps with LB 2x80 lamps, lamp suspension height - 8 m, power reserve factor K = 1.5.

We determine the specific power of the lamps W=19.6 W/m (Table 7.4).

The number of lamps is determined by the formula

where P is the power of the lamp in the lamp, we take – P = 80 W;

n is the number of lamps in one lamp, we take – 2;

W - specific power value;

S-area of the room, m2;

3.4 Ventilation calculation

When calculating artificial ventilation, we determine the necessary air exchange in the exhaust probes of the engine section, we will accept such probes - 1 area of each probe - 1.6 m2,

We determine the type of TsAGI 4-70 No. 7 fan that has the required performance at a pressure of 600 Pa.

Fan type - centrifugal, impeller diameter - 700 mm, transmission type - direct, efficiency = 0.77, shaft speed n = 950 rpm.

The installed power of the electric motor is determined by the formula

Nset=α N,kw.

Where: N is the power consumed by the fan, determined by the formula

where A is the fan performance, we take A = 12000 m3/h.

N - pressure created by the fan, Pa, N=600 Pa (page 15).

Fan efficiency, assume -0.8 (Figure 1.5);

Transmission efficiency, accept -1 (page 42)

α - power reserve factor is determined from the table. 1.2 α=1.3.

electric motor - 4А225М6У3, power 37 kW, shaft rotation speed - 930 rpm. .

3.5 Fire safety

Fire, as defined by the CMEA standard 383-76, is an uncontrolled combustion that develops in time and space. It causes great material damage and is often accompanied by accidents with people. Hazardous fire factors affecting people are: open fire and sparks; increased temperature of air and various objects; toxic combustion products; smoke; reduced oxygen concentration; explosion; collapse and damage to buildings, structures and installations.

The main causes of fires at motor vehicles are careless handling of fire, violation of fire safety rules during welding and other hot work, violation of rules for the operation of electrical equipment, malfunction of heating devices and thermal furnaces, violation of the operating conditions of devices for heating vehicles, violation of fire safety rules for battery and painting work, violation of rules for storing flammable and combustible liquids, spontaneous combustion of lubricants and cleaning materials, static and atmospheric electricity, etc.

When operating rolling stock, the most common causes of fires are malfunction of the electrical equipment of the vehicle, leakage of the power system, failure of the seal of gas equipment on a gas-cylinder vehicle, accumulation of dirt and oil on the engine, the use of flammable and combustible liquids for engine washing, gravity supply of fuel, smoking in the immediate vicinity from the power system, the use of open fire to heat the engine and when identifying and troubleshooting mechanisms, etc.

Eliminating the causes of fires is one of the most important conditions for ensuring fire safety at ATPs.

Fire prevention is a set of organizational and technical measures aimed at ensuring the safety of people, preventing fire, limiting its spread, as well as creating conditions for successful fire extinguishing. These measures at the ATP include fire safety measures provided for in the design and construction of enterprises and taken during the maintenance and repair of vehicles.

Fire safety in accordance with GOST 12.1.004-85 is ensured by organizational and technical measures and the implementation of two interrelated systems: a fire prevention system and a fire protection system.

Organizational and technical measures include: organizing fire protection at the enterprise; certification of substances, materials, technological processes and ATP facilities in terms of ensuring fire safety; organizing training for workers in fire safety rules; development of instructions on the procedure for working with flammable substances and materials, on compliance with fire safety regulations and on the actions of people in the event of a fire; organizing the evacuation of people and cars. The organization of fire-fighting visual agitation and propaganda, the use of safety signs in fire-hazardous places in accordance with the requirements of GOST 12.4.026-76 is important.

Fire safety of motor vehicles must meet the requirements of GOST 12.1.004 - 85, building codes and regulations, standard fire safety rules for industrial enterprises and Fire Safety Rules for public road transport enterprises.

The territory of the ATP must be kept clean and systematically cleared of production waste. Oily cleaning materials and production waste should be collected in specially designated areas and removed at the end of work shifts.

Spilled fuel and lubricants must be cleaned up immediately.

Roads, driveways, approaches to buildings and fire water sources, fire breaks between buildings and structures, and approaches to firefighting equipment and equipment must always be free.

To avoid fire, smoking and open flames are not allowed near parking areas and storage of flammable materials.

Production, office, administrative, utility, warehouse and auxiliary premises must be cleaned in a timely manner, technological and auxiliary equipment must be cleared of flammable dust and other combustible waste. Passages, exits, corridors, vestibules, stairs must be free and not cluttered with equipment, raw materials and various objects.

At the entrance to the production premises there must be an inscription indicating its category and classes of explosion and fire hazard.

In the basements and ground floors of industrial buildings it is prohibited to store flammable and explosive substances, cylinders with gases under pressure, and substances with an increased explosion and fire hazard, and in basements with exits to the common staircases of buildings - flammable substances and materials.

In workshop storerooms for storing flammable and flammable liquids, storage standards are established.

At workplaces in industrial premises, flammable and combustible liquids (fuel, solvents, varnishes, paints) are stored in tightly closed containers in quantities not exceeding the shift requirement.

Smoking in industrial premises is allowed only in specially designated areas equipped with water tanks and trash cans. In these places there must be a sign posted that says “Smoking Area”.

In production and administrative buildings of ATP it is prohibited:

block the passages to the location of primary fire extinguishing equipment and to internal fire hydrants;

clean premises using flammable and combustible liquids (gasoline, kerosene, etc.);

leave burning stoves, electric heating devices connected to the electrical network, unpowered technological and auxiliary equipment, flammable and hot liquids in the premises after finishing work, not put away in specially designated areas or storerooms;

use electric heating devices in places not specially equipped for this purpose;

use home-made heating appliances;

warm frozen pipes of various systems (plumbing, sewerage, heating) using open fire;

carry out work using open fire in places not provided for this purpose, as well as use open fire for lighting during repair and other work;

store containers containing flammable and combustible liquids.

To eliminate conditions that could lead to fires and fires, all electrical installations should be equipped with short-circuit current protection devices. It is necessary to connect, branch and seal the ends of wires and cables using crimping, welding, soldering or special clamps. Lighting and power lines are installed in such a way as to prevent the luminaires from coming into contact with flammable materials. Oil-filled electrical equipment (transformers, switches, cable lines) is protected by stationary or mobile fire extinguishing installations.

Air heating and heating devices are located in such a way that they are easily accessible for inspection. In rooms with significant emissions of flammable dust, heating devices with smooth surfaces that prevent the accumulation of dust are installed.

Ventilation chambers, cyclone filters, and air ducts are periodically cleaned of combustible dust accumulated in them.

If vapors of flammable liquids or explosive gases are emitted in the premises, ventilation systems with regulators and fans that prevent sparking are installed in them. Ventilation units serving fire and explosion hazardous areas are equipped with remote devices for turning them on or off in case of fires.

When servicing and operating vehicles, the following fire safety rules must be observed. Units and parts must be washed with non-flammable compounds. It is possible to neutralize engine parts running on ethyl gasoline by washing them with kerosene in places specially designated for this purpose.

Vehicles sent for maintenance, technical repair and storage must not have fuel leaks, and the necks of the fuel tanks of vehicles must be closed with caps.

If it is necessary to remove the fuel tank and when repairing fuel lines, the fuel is drained. Draining fuel is mandatory during maintenance and repair of passenger cars on a rotary stand.

When servicing and repairing gas equipment in gas-cylinder vehicles, special care should be taken to avoid sparking. To do this, use a tool made of non-sparking metals (aluminum, brass). Maintenance and repair of electrical equipment of a gas-cylinder vehicle is carried out with the valves of the gas equipment closed, and after the engine compartment has been ventilated.

In order to prevent a fire in a vehicle, it is prohibited:

Allow dirt and oil to accumulate on the engine and its crankcase;

Leave oily cleaning materials in the cabin and on the engine;

Operate faulty power system devices;

Supply fuel by gravity or other means if the fuel system is faulty;

Smoking in the car and in close proximity to power supply devices;

Heat the engine with an open flame and use an open flame when determining gas leaks through leaks.

The number of cars in parking areas, maintenance and repair rooms should not exceed the established norm. They should be placed taking into account the minimum permissible distances between vehicles, vehicles and building elements.

Tankers for transporting flammable and combustible liquids are stored in one-story premises, isolated from other premises by walls with a fire resistance limit of at least 0.75 hours. In open areas they are stored in specially designated areas.

3.6 Safety precautions

Working conditions at road transport enterprises are a set of factors in the working environment that influence human health and performance during the work process. These factors are different in nature, forms of manifestation, and the nature of their effect on a person. Among them, a special group is represented by dangerous and harmful production factors. Their knowledge makes it possible to prevent occupational injuries and diseases, create more favorable working conditions, thereby ensuring safety. In accordance with GOST 12. O. 003-74, hazardous and harmful production factors are divided according to their effect on the human body into the following groups: physical, chemical, biological and psychophysiological.

Physical hazardous and harmful production factors are divided into: moving machines and mechanisms; moving parts of production equipment and technical equipment; moving products, parts, units, materials; increased dust and gas contamination of the air in the working area; increased or decreased temperature of the surfaces of equipment and materials; increased or decreased air temperature in the working area; increased noise level in the workplace; increased level of vibration; increased level of ultrasound and infrasonic vibrations; increased or decreased barometric pressure in the work area and its sudden change; increased or decreased air humidity, air ionization in the work area; lack or lack of natural light; insufficient illumination of the work area; reduced contrast; increased light brightness; sharp edges, burrs and roughness on the surfaces of workpieces, tools and all equipment.

Chemical hazardous and harmful production factors are divided according to the nature of the impact on the human body into toxic, irritating, sensitizing, carcinogenic, mutagenic, affecting reproductive function, and according to the route of penetration into the human body - into those penetrating through the respiratory system, gastrointestinal tract, skin and mucous membranes.

Biological hazardous and harmful production factors include the following biological objects: pathogenic microorganisms (bacteria, viruses, fungi, spirochetes, rickettsia) and their metabolic products; microorganisms (plants and animals).

Psychophysiological dangerous and harmful production factors, according to the nature of their action, are divided into physical and neuropsychic overloads on a person. Physical overload is divided into static and dynamic, and neuropsychic overload into mental overstrain, overstrain of analyzers, monotony of work, emotional overload.

During the maintenance and routine repairs of vehicles, the following dangerous and harmful production factors arise: moving vehicles, unprotected moving elements of production equipment, increased contamination of premises with exhaust gases from passenger cars, danger of electric shock when working with power tools, etc.

Safety requirements for vehicle maintenance and repair are established by GOST 12. 1. 004-85, GOST 12. 1. 010-76, Sanitary rules for the organization of technological processes and hygienic requirements for production equipment, labor protection rules in road transport and fire safety rules for service stations.

Process equipment must meet the requirements of GOST 12. 2. 022-80, GOST 12. 2. 049-80, GOST 12. 2. 061-81 and GOST 12. 2. 082-81.

In the maintenance zone and in the repair zone, to ensure safe and harmless work of repair workers, reduce labor intensity, and improve the quality of work on maintenance and repair of vehicles, work is carried out at specially equipped posts equipped with electromechanical lifts, which, after lifting the car, are secured with special stoppers, various devices, devices, instruments and inventory. The car on the lift must be installed without distortions.

To prevent electric shock to workers, lifts are grounded. For the work of repair workers “from below” the car, individual lighting of 220 volts is used, which are equipped with the necessary safety equipment. Removal of units and parts, associated with great physical stress and inconvenience, is carried out using pullers. Units filled with liquids are first emptied of them, and only then removed from the vehicle. Light parts and units are carried manually, heavy units weighing more than

Design of a mechanical repair workshop. Determining the number of maintenance and repairs. Calculation of artificial lighting of the plumbing and mechanical section. Selection of repair and technological equipment. Calculation of the number of repairs trucks per cycle.

Development of a design for a service station and car repair areas. Calculation of the production program for maintenance and repair. Features of organization and production management, safety precautions and labor protection at car service enterprises.

The technological process of repairing a tire of a VAZ 2108 car, using advanced methods of organizing auto repair production in the conditions of the production facility of MTK LLC. Features of environmental protection and fire prevention measures at the tire workshop.

Calculation of the frequency of maintenance and repair, determination of the frequency of vehicle mileage. Calculation of the technical readiness coefficient, determination of the fleet utilization rate. Technical documentation of the service system.

Assignment Develop a project on the topic “Organization of work, aggregate section complex of repair areas of ATP in Voronezh.” Design assignment:

Production and technical documentation in managing the processes of current repair (TR) of vehicles in the conditions of motor transport enterprises (ATE). Development of a document flow diagram. Comparative analysis organization of maintenance and repair of rolling stock at ATP.

Design of labor organization at vehicle maintenance stations. Brief description of the repair team. Description of the technology for carrying out a complex of maintenance and repair works. Labor protection requirements and safety requirements for vehicle maintenance.

1. INTRODUCTION Efficiency of use vehicles depends on the perfection of the organization of the transport process and the properties of cars to maintain, within certain limits, the values of parameters characterizing their ability to perform the required functions. During the operation of the car...

Characteristics of a motor transport enterprise. Calculation of the maintenance area, its area, annual volume of work, number of workers. Choosing a method for organizing the technological process. Analysis of management organization technical service ATP.

Characteristics of the motor transport enterprise and the design object. Calculation of the car maintenance program. Calculation of the shift program. Selection of technological equipment. Mechanization of production processes in departments.

Characteristics of a vehicle repair shop for chassis repairs. Calculation of the frequency of maintenance of the corresponding type. Determination of the daily production program. Distribution of labor intensity by type of work. Organization of labor at the design site.

Calculation of the annual volume of work at a car service station, their distribution by type and location. Calculation of the number of workers, number of posts and car-waiting and storage places. Determination of areas and equipment needs.

Technological calculation of the required space, amount of equipment and technological interconnection of production departments and equipment of the ATP. Calculation of areas of maintenance and repair zones, production areas, storage facilities, car storage areas.

Characteristics of the studied motor transport enterprise and design object. Operating conditions of rolling stock. Calculation and adjustment of maintenance frequency and mileage before major repairs. Calculation of specific labor intensity.

Choosing a rational method for restoring a part. Development of a list of operations for the repair process of the ZIL-130 cylinder block. Equipment for welding and surfacing area. Calculation of allowances for machining. Selection of cutting and measuring tools.

Technological justification for the project of a motor transport enterprise. Determining the number of maintenance and repairs per cycle. Determination of the annual volume of maintenance and repair work. Production places.

Designing the annual volume of work at a service station in accordance with standards and reference data. Determination of the number of jobs, number of engineering and technical workers. Calculation of workshop area, requirements for basic resources. Rationale for the graphic part.

Workshop characteristics fuel equipment. Calculation of the annual production program. Calculation of the number of production workers. Organization of the production process for repairing APT rolling stock at the site. Fuel shop control diagram at ATP.

General characteristics of ATP. Name, address and purpose: Transport section No. 14. Address: Tutaev st. Promyshlennaya 8 Designed for scheduled repairs and technical

The engineering and technical service includes the following production areas and complexes:

Maintenance and diagnostics complex (TOD), which unites performers and teams of EO, TO-1, TO-2, and diagnostics;

The TR complex, which combines units that carry out repair work directly on the vehicle (guard units);

A complex of repair areas (RU), which brings together departments and performers engaged in the restoration of the working capital of units, components and parts.

ITS includes the following subsystems (divisions, departments, workshops, areas):

ITS management represented by the chief engineer responsible for the technical condition of vehicles, their road and environmental safety;

Group (center, department) for production management of vehicle maintenance and repair;

Technical department, where planning solutions for the reconstruction and technical re-equipment of the production and technical base are developed, the selection and ordering of technological equipment, and the development of technological maps are carried out; occupational health and safety measures are developed and carried out, the causes are studied industrial injuries and measures are taken to eliminate them; technical training is carried out to train personnel and improve the qualifications of personnel; technical standards and instructions are drawn up, non-standard equipment, fixtures and fittings are designed;

Logistics department, which provides logistics, preparation of supply requests and effective organization warehouse operations. One of important conditions improving the use of rolling stock, increasing its technical readiness is the timely provision of ATP with fuel, spare parts, tires, garage and repair equipment. The accurate implementation of production indicators, the rhythmic operation of the enterprise, and increased labor productivity depend on the rational use of material and technical means. Economical use of resources and reduction of their consumption reduces the cost of transportation.

The logistics department (MTO) must provide production with the necessary material resources and monitor their consumption and use.

The logistics plan consists of separate calculation tables classified by type of materials:

The need for fuel, lubricants and operating materials, tires, spare parts;

Demand for fuel for technological purposes and electricity;

Demand for rolling stock and equipment.

The purpose of this type of planning is to save material resources by various factors, as well as control over the consumption of materials.

The logistics department (MTS) is tasked with determining the need for various types raw materials and materials, equipment, etc.

Figure 3.1 - Scheme for managing the consumption of operating materials

The share of fuel in the total cost of transportation is 15-20%. Therefore, saving fuel and lubricants (LCM) is important as a factor not only in reducing costs road transport, but also a reduction in energy resources.

The Operations Department is prohibited from accepting waybills that do not contain information about the issuance of TCM. After processing the waybills in the operation department, they are submitted to the FCM accounting group, where actual and normal flow fuel for each car. The fuel metering technician fills out a registration card for each vehicle and the driver’s personal account, which records the completed transport work, number of rides, fuel consumption according to the norm and actual. Fuel consumption is monitored for the vehicle and driver in liters, and for the vehicle as a whole - in kilograms.

The list of materials that are used to meet the economic needs of ATP is quite large. Among them are cutting and measuring tools, electronic and technical materials, and workwear. Logistics workers who supply the enterprise need to order them in advance and in the right quantities, receive them on time, properly distribute and store them. The company's need for spare parts depends on large number factors that can be characterized by the following groups: constructive, operational, technological and organizational. The technical control department, which monitors the completeness and quality of work performed by all production departments, controls the technical condition of the rolling stock when it is received and released onto the line. Production preparation complex that carries out production preparation, i.e. completing the working stock of spare parts and materials, storing and regulating inventories, delivering units, components and parts to work stations, washing and completing the repair stock, providing workers with tools, as well as driving vehicles in maintenance, repair and waiting areas. Organization of production of maintenance and repair of vehicles in 121-PCh GU PTC FPS for Sverdlovsk region produced by the aggregate-sectional method. Which consists in the fact that all maintenance and repair work on rolling stock is distributed among production areas responsible for performing all maintenance and repair work on one or more units (units, mechanisms, systems) for all vehicles in the fleet (Figure 3.2).

Figure 3.2 - Structure of the engineering and technical service when organizing the production of maintenance and repair according to the aggregate-sectional method

The technical and economic performance indicators of enterprises largely depend on the condition and performance of equipment, the organization of its operation and maintenance, and timely and high-quality repairs.

An important role in organizing the maintenance and repair of equipment is given to the introduction of a system of planned maintenance and repair of equipment (PTOR) at enterprises.

The purpose of the PTOR system is to ensure the planning and implementation of maintenance and repair within a certain time frame in the required sequence and scope of work.

The system of planned maintenance and repair of equipment is a set of organizational and technical measures for maintaining documentation of maintenance and repair; providing personnel who maintain the equipment in good condition and ensure the quality indicators of machines and devices established by regulatory documentation.

The PTOR system includes several types of maintenance and repair, which differ from each other in the content of work and the use of technical means.

The PTOR system provides for: systematic observation and periodic inspection, allowing timely identification and elimination of equipment malfunctions; conducting maintenance of equipment during its operation in established modes; planning and carrying out maintenance and repairs; application of progressive repair methods using mechanization and advanced techniques for restoring parts and assemblies.

Responsibility for the general organization and conduct of PTOR activities rests with the chief engineer and chief mechanic (energy engineer) of the enterprise.

The PTOR system includes two types of work: inter-repair maintenance and carrying out scheduled repair work on time.

Equipment Maintenance. Maintenance (MA) is a set of operations to maintain the serviceability and performance of equipment when used for its intended purpose and stored; is performed during equipment operation, on days of disinfection by operating personnel and repair service personnel on duty.

Maintenance during the use of equipment for its intended purpose is carried out in accordance with the operating instructions (maintenance instructions) developed by the enterprise. Maintenance costs are included in operating costs.

The condition and performance of equipment is recorded every shift in the equipment acceptance and delivery log for shifts. The correctness of the journal is monitored by a plant (shop) mechanic once a day with mandatory written confirmation of the control.

Regulated maintenance is carried out routinely in accordance with the annual schedule. The range of regulated maintenance works includes: monitoring the technical condition of equipment; inspection; elimination of detected defects; adjustment; replacement of individual components of equipment; cleaning, lubrication.

The results of inspection of equipment performed during regulated maintenance are noted in the log. The log data is the source material for establishing the volume of work performed during the next scheduled repair.

To monitor the condition of equipment at the enterprise at least once a quarter (according to certain species equipment - monthly) inspections of equipment are carried out by engineering and technical personnel of the chief mechanic and power engineer service.

Types of repairs. The PTOR system provides for the following types of repairs: current (T 1; T 2) and capital (K).

Routine repairs of equipment are carried out both during the repair period and during the operation of the equipment to ensure the restoration of its functionality; consist of restoration or replacement of individual parts and assembly units.

Depending on the nature and volume of work, current repairs are divided into the first current (T 1) and the second current (T 2).

Major repairs are carried out with the aim of complete restoration or close to full of resources equipment with or without replacement of its parts.

The cost of current and major repairs is attributed to the repair fund created at enterprises according to the standards for repair costs.

The nature and scope of work performed during major and current repairs are established in accordance with the list of defects and are clarified during the process of disassembling and repairing equipment. Work aimed at improving technical and technological parameters is classified, depending on the volume, as modernization or reconstruction. They are planned at the time of major repairs and are financed through capital investments with an increase in the book value of fixed assets. Responsibility for their implementation rests with the chief engineer of the enterprise.

Forms of repair organization. In the alcohol industry, intra-factory and inter-factory forms of organizing repair production have been adopted.

In the in-plant form, centralized repairs of equipment are provided by the mechanical repair shop (electrical shop) of the enterprise.

During the repair period to achieve high performance labor, increasing the responsibility of performers for the repair of specific equipment, workers servicing this equipment are included in the repair team. At the same time, teams should select the same type of equipment, which will make it possible to more rationally use the qualifications of workers, devices and tools. The distribution of work among team members is carried out by the foreman in agreement with the plant (shop) mechanic. Repair items are distributed by the chief mechanic in agreement with the chief engineer of the plant. Lists of repair teams with repair objects assigned to them are approved by order of the director.

The inter-factory form of organizing repair work provides for:

carrying out unit repairs of complex, large-sized and unique equipment in general and individual nodes at specialized repair plants, workshops and commissioning plants;

centralized provision of enterprises with spare parts and assembly units for industry purposes, as well as standardized parts and assembly units coming from machine-building plants that produce relevant types of equipment, and from specialized factories for the production of spare parts.

Forms of organizing repairs at alcohol industry enterprises are used depending on the conditions for organizing repair services.

The following repair methods are used at enterprises:

impersonal, in which the belonging of the restored components to a specific piece of equipment is not preserved. According to the organization of implementation, this repair method can be aggregate (faulty units are replaced with new ones or previously repaired) and detailed (individual parts that have failed are replaced or restored);

an impersonal repair method in which the restored components remain belonging to a specific piece of equipment.

The choice of method is based on the conditions for the greatest production and economic effect.

Planning and execution of repairs. All types of repair work are subject to planning. The implementation of the repair plan is mandatory for enterprises in the same way as the implementation of the main product production plan.

The repair plan for equipment controlled by Gosgortekhnadzor is drawn up separately from the repair plan for technological, power and general plant equipment and should not be linked to it.

The annual repair plan is integral part technicalpromfinplans. The scope and range of repair work must ensure uninterrupted and efficient work park of technological, energy and general plant equipment. The labor intensity and cost of the work are compared with the corresponding indicators of the technical industrial and financial plan and provide for the workload of workers and equipment of the repair and services involved in the repair. Repairs begin after the end of the production period.

The postponement of equipment shutdown for repairs is carried out in exceptional cases with the permission of the chief engineer of the enterprise, and for equipment subordinate to Gosgortekhnadzor, it is agreed with the regional bodies of Gosgortekhnadzor.

The annual repair plan is drawn up by the chief mechanic (power engineer) service, taking into account data on the availability of equipment and the list of works (Form 5); equipment affairs; logs of acceptance and delivery of equipment by shift, results of its inspection during scheduled maintenance; lists of defects; reports on previously completed repairs; standards for the frequency and duration of current and major repairs (forms 3, 4); requests from production shops; the duration of the plant shutdown for repairs.

Based on the annual equipment repair plan, the total volume of repair work for the enterprise as a whole is determined.

Each enterprise is required to draw up annual and monthly schedules of planned repairs.

The annual schedule of planned repairs for the enterprise is drawn up by the chief mechanic (energy) service and approved by the chief engineer.

Monthly schedules are compiled by the chief mechanic service on an annual basis, specifying the date of stops for repairs and their duration. If necessary, the monthly schedule includes repairs not covered by the annual schedule.

The monthly schedule is approved by the chief engineer of the enterprise and is the main document regulating equipment repairs and production planning for a given month.

For each piece of equipment that is subject to major or routine repairs at intervals of one year or more, the chief mechanic service prepares an estimate of repair costs.

The estimate is calculated according to expense items: basic wages of workers; bonuses; materials, semi-finished products, finished products (purchased and own production); shop expenses; general plant expenses.

Salaries and bonuses are calculated in accordance with the current enterprise standards for the tariff schedule and the provisions on bonuses for high-quality performance and reduction of repair time.

Expenses under the item “Materials, semi-finished products, finished products” are determined according to the object standards for material consumption for the repair of this type of equipment or on the basis of existing experience in organizing the repair of equipment at the enterprise.

Shop and general plant expenses are determined as a percentage of the basic salary of repair workers in accordance with the technical industrial and financial plan of the enterprise.

Tariffication of work during equipment repair is carried out according to the tariff and qualification directory, which contains production characteristics of all types of work with the tariff categories established for them.

The standard unit is the volume of work on major repairs with the established standard of labor costs (in man-hours) per unit of repair complexity (Table 1).

Spare parts standards for repair and operation. The range of spare parts is established based on an analysis of their consumption and based on the service life of parts and assembly units.

The range of spare parts includes:

parts and assembly units whose service life does not exceed the duration of the overhaul period;

parts and assembly units that are consumed in large quantities and whose service life exceeds the duration of the overhaul period;

parts and assembly units that are labor-intensive to manufacture, ordered from a third party and limiting the operation of the equipment;

parts and assembly units for imported equipment, regardless of service life;

purchased products (ball bearings, cuffs, belts, chains).

Consumption rates are developed according to the range of spare parts and are calculated based on the number of parts or assembly units per unit of equipment and their service life.

A list of spare parts for each type of equipment is compiled by the chief mechanic’s service and entered into the equipment file.

Spare parts storage standards. During the year, the company's warehouse stores spare parts, purchased products and materials in quantities sufficient to ensure the repair and operation of equipment. As they are used up, their supply is restored.

Warehouse stock standards are determined in accordance with the standards annual needs in spare parts for each type of equipment. When determining stock standards, the formation of unreasonably large stocks of individual parts is not allowed.

Inventory standards are calculated based on an analysis of the range of spare parts, taking into account the average service life of parts per unit of equipment, as well as the time to replenish the stock.

The number of spare parts of one type to be stored in the enterprise warehouse is determined by the formula

Z = BONK/C 3,

where B is the number of similar spare parts in a piece of equipment; O - number of units of the same type of equipment; I - frequency of receipt of parts from the manufacturer, months (usually 3, 6, 12 months); K - reduction factor, taking into account the similarity of parts in a group of equipment; From 3 - service life of the spare part, months.

The value of K is given below.

The company revises and adjusts the nomenclature and storage standards for spare parts at the suggestion of the chief mechanic service at least once a year during the initial period of creating a spare parts fleet (during the first two to three years) and at least once every two years thereafter .

Responsibility for timely and complete provision of the enterprise with all necessary materials and spare parts are entrusted to the head of the logistics service, and for the provision of spare parts manufactured in mechanical repair shops (RMM) - to the chief mechanic of the enterprise.

Control over the storage conditions and condition of the spare parts fleet at the enterprise is carried out by the chief mechanic service.