Equipment is the basis of the company's production and operation activities. Under the rapid development of printing technology, equipment has become an important part of the company's core competitiveness. Equipment management should achieve two results: First, the technical status of equipment is the best, and second, equipment maintenance and management costs are the most economical. In modern management concepts, costs refer not only to direct production costs but also to management costs such as quality costs and equipment costs.

First, the cost of equipment

The ultimate goal of equipment cost management is to ensure low costs in all aspects of equipment management under the overall planning of the company's business strategy, and to strive for the lowest equipment life cycle cost.

Equipment management costs mainly include acquisition costs (which directly affect depreciation expenses), labor costs for maintenance and equipment management, maintenance materials (mainly spare parts), outside maintenance costs, and losses from work stoppages.

The control of equipment management costs is not passive control, and more equipment costs should be changed from uncontrollable costs to controllable costs so as to achieve the goal of reducing total costs.

1, equipment management
To effectively control equipment costs, we must first establish a sound and effective equipment management system. The comprehensive management of equipment is the core content of modern equipment management concepts. After experiencing the traditional equipment management phase based on after-service maintenance and preventive maintenance, it comprehensively manages all material movement patterns and value movement patterns in the equipment life cycle. Become the mainstream concept of modern equipment management, and become an effective means of equipment maintenance cost control.

The theory and method of integrated equipment management mainly include integrated equipment engineering and equipment maintenance system. Integrated equipment engineering is the theory that comprehensively studies the related engineering technology, management, finance, and other actual operations to achieve the most economical life cycle cost of the equipment. The full equipment maintenance system includes the meanings of preventing maintenance and production and maintenance, and requires the equipment to have the best overall efficiency. It requires that the entire life cycle be the object of the entire process management, and requires all employees to participate in equipment management.

The entire process of equipment management includes research, design, trial production, manufacture, purchase, installation, commissioning, use, maintenance, renovation, renewal, and retirement. Maintenance is only a small part of the work, but it is the most obvious part of the cost of corporate equipment. From an overall point of view, to reduce maintenance costs, it must be coordinated with the work of other sectors and do a good job of managing all aspects. The whole process management can overcome and prevent two disconnections: one is the disconnection between the first half of the equipment (production and installation) and the latter half (use and maintenance), and the strengthening of the horizontal connection with the equipment manufacturing unit and the use department; the second is to overcome The disconnection between the internal and external links in the latter half of the year will be reinforced by the coordination and cooperation among the relevant internal units and the good management of equipment.

The equipment comprehensive efficiency analysis method can be applied, and the annual cost method and the present value method can be used to quantitatively measure the life cycle cost of the equipment so as to achieve the objective of obtaining the lowest equipment life cycle cost and the highest overall efficiency. Can not just save equipment purchase costs, regardless of whether the use of economic costs and the greatest contribution to the company; can not only seek to save on the use of costs, regardless of the level of purchase costs.

The equipment cost control of a printing company should consider the comprehensive control method of equipment life cycle cost from the perspective of equipment comprehensive management, overcome the concept of relying solely on the individual control of each management link, and consider the problem from an overall perspective.

Second, comprehensive cost control points

The guideline for the use of equipment is to love the use of equipment, not only to protect the equipment, but more importantly it is also necessary to prevent the equipment from being idle. The main points of comprehensive cost control for equipment are the following aspects.

1. Pay attention to the inspection of equipment maintainability

The maintainability of equipment is an important measure to reduce maintenance costs and reduce downtime losses. Especially for some bottlenecks, the maintainability of equipment is more important. Therefore, depending on the importance of the equipment, it is necessary to pay attention to the equipment when purchasing equipment. Inspection of maintainability.

2. Do a good job in equipment investment forecast

Equipment not only affects the quality of the company's products, but also has the most direct impact on the variety of products. In today's rapid development of printing technology, equipment as a direct carrier of science and technology, its role and influence is increasing, such as the use of CTP process will require the introduction of CTP platesetter, digital printing, there must be a digital printing machine. At the same time, the rapid renewal of technology also makes it more and more difficult to forecast equipment investment. Equipment investment is a strategic investment, and the impact of inaccurate equipment investment forecasts is difficult to compensate through routine management. For example, the quality of products printed using domestic newspaper printers is difficult to compare with that of imported equipment from Germany. In short, under the circumstance of more accurate grasp of technology and market, it strives to achieve advanced technology, economical rationality, feasible production, upgraded structure and rationalization.

3. Use value engineering to guide equipment purchase

The use of value engineering, taking into account life-cycle costs and the use of benefits, is a basic requirement for the purchase of modern equipment and an effective method for controlling the overall cost of equipment. Value engineering is to achieve the best functional benefits with the lowest life-cycle costs. Life cycle costs include not only acquisition costs but also usage costs. Therefore, when the equipment is purchased, it is necessary to comprehensively analyze the purchase cost, quality, performance, maintainability, use and maintenance costs of the equipment, and consider the economic benefits, product quality, and production efficiency to obtain the best value. For example, in the selection of printing presses, in the trade-offs of various brands, German equipment, Japanese equipment, or domestic equipment can be selected, and comprehensive analysis can be performed using value engineering.

4. Master the equipment wear law and fault law

The equipment wear can be roughly divided into three stages, initial wear stage, normal wear stage and severe wear stage, which should be used in the initial wear stage, carefully maintained during normal wear stages, and repaired before the severe wear stage. Correspondingly, the failure change law of equipment can also be roughly divided into three stages, namely initial failure period, accidental failure period and wear-out aging failure period. The requirements are careful installation, careful commissioning, enhanced commissioning, and strict acceptance in the initial failure period; enhanced maintenance during occasional failures; timely preventive maintenance and improved maintenance before entering the wear-out failure period, with emphasis on economic and technological deterioration. In the new situation of rapid development of printing technology, we must pay attention to the economy. The basic approach to dealing with technological degradation is to increase the efficiency of production and operation of equipment, prevent equipment from being idle, and update it in time before the technology deteriorates.

5. Maintenance economy

The higher the maintenance guarantee, the lower the equipment downtime loss and deterioration loss, but the more the cost, the printing industry is a service-oriented industry, the loss of downtime is huge, not only has direct economic losses, but also indirect because it can not The effect on the reputation of the company arising from delivery on schedule. This is even more noticeable in the newspaper industry, so it also needs to increase maintenance investment accordingly.

6. Selection of equipment maintenance methods

The preventive maintenance system is a maintenance system that modern companies should consider first. Under this maintenance system, it can be divided into routine maintenance, post-event maintenance, preventive maintenance, production maintenance, improved maintenance, and predictive maintenance. There are great differences. According to different equipment and different situations, a variety of maintenance methods should be used comprehensively to ensure the normal operation of equipment and reduce maintenance costs. First of all, it can be selected according to different types of faults, such as the implementation of predictable maintenance of faults that are easy to monitor, and regular maintenance of maintenance and faults. Second, according to the different economical choice of maintenance methods, the maintenance costs, preventive maintenance fees, condition monitoring fees, and downtime loss fees will be compared, and the least costly repair method will be selected. Again, the maintenance mode is selected according to the different degradation modes of the equipment. Predictive maintenance is a better maintenance mode.

7. Full equipment management

The equipment classification and split management is the basic requirement for equipment management. Instead of relying solely on the equipment department to go it alone, it is necessary to organize all personnel related to the equipment into the equipment management. Through perfect post responsibility system, equipment management is established on the basis of On the basis of a broad mass of people, this is the most effective way to reduce the cost of equipment management. The specific approach is to fully mobilize the enthusiasm of the functional departments of all sectors, especially the management personnel, and correctly handle the contradictions and interests arising from the division of labor from the horizontal sequence; from the longitudinal sequence, it is necessary to mobilize the personnel at all levels. The enthusiasm, especially the enthusiasm and initiative of the operators, and their full trust in them can effectively solve various problems in the operation of the equipment. Practice has proved that companies form a good combination of horizontal and vertical sequences, professional equipment management network combined with the masses, can effectively improve equipment management efficiency. (to be continued)