Management regulations of die casting workshop

Each workshop needs to have its own production management system, so how to formulate the relevant management regulations of die casting workshop? I'll provide you with some information about the management regulations of die casting workshop, hoping it will help you.

The management regulations of die casting workshop are as follows: 1. Safety management regulations:

Die casting production is a special type of work with high temperature and high pressure, and safety production is the first. Every employee should maintain a high awareness of industrial safety during and after the operation, do a good job of sorting out and strictly abide by the operating specifications, so as to achieve? Go to work happily and go home safely? The ultimate goal of industrial safety, safety management specification * * * 18, points out as follows:

1. Wear long-sleeved overalls, work shoes and gloves before going to work, and wear protective covers when feeding.

2. Don't put anything on the aisle, work on the aisle.

3. Be sure to be proficient in fire prevention operation and accident handling methods.

4. The location and usage of fire extinguishers must be skilled.

5. If the crucible is found to be leaking, stop the machine in time, cut off the power supply, oil supply and gas supply, especially check whether the burner is turned off, and use metal objects and dry soil as barriers to prevent the zinc liquid from flowing out.

6. Should pay attention to whether the burner leaks oil, and immediately report to the foreman for processing, in case of fire.

7. If oil and gas leakage is found, stop the machine in time to check and take measures, and then resume production after thorough solution.

8. In case of fire caused by unexpected situations such as material leakage, oil leakage and air leakage, the power supply and oil and gas source should be cut off in time, and dry powder fire extinguishers should be used to put out the fire at the same time to prevent the situation from further expanding. It is forbidden to put out fires with water.

9. Pay attention to the inviolability of moisture in the crucible during production and prevent leakage when it rains. It is forbidden to boil water and heat food on the crucible to prevent the molten zinc in the crucible from exploding in water.

10. The zinc ingot at the head should be put into use in a dry state. Without permission, oil is not allowed, and the crumbs with water in the head should be poured into the crucible.

1 1. The zinc slag recovered from the crucible must be put in a dry cast iron tank, not on the floor, to avoid the danger of explosion.

12. If the main switch needs to be turned off due to electrical system failure, please report and do not disassemble it without permission.

13. Screen should be used in the middle of each die casting machine to prevent material from splashing and hurting people.

14. Pay attention to the danger of material splashing when passing through the die casting machine.

15. Operators and charging personnel should distinguish their work, greet and cooperate with each other during charging operation, and discourage non-production personnel from entering unsafe areas.

16. Two people should cooperate to change molds. When replacing the mold, you should carefully confirm the safety before moving and lifting it. Work hard. When locking the mold, use more than three screws, and pay attention to check whether the threads of the locking screws are in good condition. It is strictly forbidden for mold to hurt people or hurt people.

17. Straighten the mold only after stopping the machine.

18. Tools and accessories should be put in the toolbox after use to prevent people from being hurt at will. It is strictly forbidden to put them in the machine.

Two: quality management standards:

In order to achieve high quality and low consumption of products, each operator should be responsible for the quality of the products he manufactures:

1. Due to initial production, shutdown and other reasons, the operator should take the initiative to return the products with surface defects and many cold lines to the furnace for cold die operation.

2. Due to the defects of parts caused by molds, machines and equipment, production should be stopped in time and reported to the foreman, who will take measures to solve them thoroughly before putting them into production.

3. The zinc residue in the slider should be cleaned in time to prevent the product size from changing.

4. For oriented products, we should always pay attention to the change of mold in production to prevent the loose mold parts from causing orientation deviation.

5. The finished blank should be placed neatly, the height of the turnover box should not exceed three layers, and the blank should not be pressed.

6. Operators in each shift should conduct self-inspection before inspection. The defective rate of inspection should be within 3%, and more than 3% inspectors will send it back for re-inspection.

7. The proportion of slag fishing shall not exceed 10% of the output.

8. Absolutely respect the rights and responsibilities of the quality control department in the production process. First of all, it must unconditionally accept the opinions of its supervisors and inspectors. If you have any objection, you should report it to the supervisor. It is strictly forbidden to quarrel with the inspectors because of quality problems, or even fight or take revenge afterwards.

3. Production management specifications:

1. Before going to work, ask the foreman about the work tasks and related matters needing attention, assist the foreman in picking materials, take over quickly and orderly, and do not deliberately delay or advance. At the same time, carefully make necessary records during the shift change.

2. At work:

A, work hard, don't talk and laugh casually, eat, read books and periodicals unrelated to work, and don't lie down, sit down or even doze off or sleep by the machine during working hours.

B, stick to their posts, do not arbitrarily string posts, and are not allowed to adjust posts or fill posts at will. If something happens, it must be approved by the foreman or supervisor. After this, you should go to work as soon as possible.

C. If any abnormality or work error is found in production, or other unsolvable problems are encountered, it shall be reported to the foreman or substitute cadres immediately, and it shall not be intentionally concealed or concealed. In order to avoid responsibility, foreman or substitute cadres should deal with it in time, and must not shirk or return to work before the problem is solved.

D, at work, you should save costs at any time, don't waste it casually, and take strict care of machinery, equipment and production tools. Do not intentionally damage, misappropriate other people's articles or engage in other activities.

E, the produced products should be self-inspected, packed according to the standard turnover box and the specified quantity, and there can be no shortage or overflow. And placed in the designated position, neatly arranged, waiting for inspection.

F, borrow warehouse tools must fulfill the registration procedures, if there is any improper loss or loss, must compensate or accept punishment.

G, the operator should take turns to eat at work, shall not stop over, foreman to ensure that there are two people at the scene at the same time.

3. Before coming off work, the products, zinc slag and unused materials made on duty should be sorted out in time, the tools should be counted, the site should be cleaned up, and the next shift should be handed over. Finally, assist the foreman to put the products into the warehouse before leaving.

4. Basic operation specifications of die casting machine:

In order to ensure the normal operation of the machine, support unnecessary machine failures and downtime, and the occurrence of accidents, every employee must follow the following specifications:

1. Operators and other relevant personnel are not allowed to adjust the parameters of the machine without authorization. If there are any abnormalities that need to be adjusted, they should report to the foreman in time, and the foreman will decide whether to adjust and implement the adjustment.

2. Observe the oil supply status of hydraulic oil and lubricating oil, machine cooling system, furnace temperature, nozzle, gooseneck temperature, hydraulic oil temperature, total pressure of hydraulic system, injection pressure and other indicating parameters, machine sound and smell. If there is any abnormality, report it to the production management system of die casting workshop in time and handle it.

3. It is not allowed to tap the soft hose on the machine guide post with the material head or other iron tools to prevent damage.

4. Die slider can't be struck with other iron tools, only with a copper bar or rubber hammer.

5. When the zinc material is completely melted, the periphery and upper edge of the furnace must be kept clean and tidy.

6. After replacing the mold or handling the mold failure, check whether the hammer can rotate, and then continue production after it can rotate.

7. In production, it is not allowed to hit the probe in the crucible with an iron clip or spoon or spill the solution to hurt people.

8. During production, after closing the mold, personnel should stand 0.8M away from the plane of the clutch mold line to avoid injury.

9. Zinc ingots should be baked before entering the furnace to prevent explosion. Generally, only one zinc ingot can be added at a time. It is forbidden to add more than one zinc ingot at a time. Secondary materials should be added alternately with zinc ingots to prevent the temperature of zinc liquid from dropping too much, resulting in abnormal molding quality.

10. When removing zinc flakes accumulated on the feed pipe, stop the machine first, and then handle it.

1 1. Anyone who handles the failure of the machine and mold should stop the machine before handling it.

12. In the production process, it is forbidden to throw the material head into the zinc liquid by force, and the material head should be put into the furnace step by step to prevent splashing.

13. In production, the packing action is carried out in strict accordance with the quantity set in the TEU.

14. It is forbidden to take oil from the hydraulic oil tank or open the cover to do other actions.

5. The basic procedure of changing the mold:

A. Get off the machine and turn off the cooling water of the mold. Remove the rubber tube and lift the mold.

B. When removing the movable formwork, it must be held by hand, and lowered after balanced lifting.

C when disassembling the fixed die, be careful not to touch the moving die to prevent the die surface from falling off.

D after the movable die and the fixed die are removed, they must be basically closed to prevent accidental injury.

E. When installing the fixed mold, when it must cooperate with the gate, the zinc block is not allowed on the gate, and it should be cleaned to prevent the mold from being damaged when it cooperates with the gate.

F. When installing cooling water pipes, pay attention to whether the inlet and outlet of cooling water are in one-to-one correspondence, and try to see if there is water leakage. At the same time, check whether the cooling water in and out of the mold is normal.

G. manually close the mold by clicking, and press the mold into place. When pressing the mold, be careful not to squeeze the nozzle.

H. adjust the mold to make it moderately elastic.

First, manually eject it gently, and pay attention to the proper adjustment of the ejector pin ejection conditions.

J. low-speed mode locking at startup.

K. adjust the machine parameters.

6. Shift change and daily inspection:

A good beginning is half the battle. Therefore, it is beneficial to people and self-interest to do a good job of succession, which is more helpful to find potential problems so as to deal with them in time and ensure long-term normal production:

1. Machine check:

Hydraulic system:

A. Check whether the hydraulic components (solenoid valves and oil pipes) leak oil.

B check whether the temperature control of hydraulic oil is normal, 40 degrees plus or minus 5 degrees, and the maximum temperature shall not exceed 55 degrees.

C. check the oil pump for noise.

D. check whether the amount of hydraulic oil is sufficient.

Electrical system:

E. Check whether the wires in each part are loose, falling off and peeling, mainly referring to the signal wire of the probe.

F. Whether the travel switches of each machine are normal.

G. Whether the action of the mode-locking system is normal, coherent and stable.

H. whether there is abnormal friction and loose sound.

First, whether the front end of the system is loose.

J. whether the back mold will be distorted when locking the mold.

K. check whether the switch mode action is coherent and smooth.

Lubrication system:

Whether the length lubricating oil tank is clean and whether the oil quantity is within the correct range.

Meter (abbreviation of meter)) Whether all elbows and connecting rods of the mode-locking system have oil and whether the oil nozzle has oil.

Cooling system:

Noun (abbreviation for noun) Whether the cooling water pipe is leaking or unblocked.

O. whether all cooling water pipes are open.

2. Mold inspection:

Page (abbreviation of page) during production, observe whether the mold is stuck with burrs and whether the overshoot is too large. If so, it needs to be dealt with immediately before continuing production.

Q. Take a product to check whether the mold is bitten or dented, and whether the length and position of each thimble are normal.

R. Whether there is abnormal sound on the clamping guide post, slider and inclined guide post during clamping.

3. Inspection of environmental sanitation and other auxiliary equipment:

The working environment around the south machine must be neat and orderly, and there must be no oil stain, zinc flake or zinc block on the ground where all materials are placed.

T. Whether the electric fan and spray gun work normally, and whether there are faults such as no phase, water leakage and air leakage. If so, it must be dealt with immediately.

Verb (abbreviation of verb) Whether the periphery of the combustion furnace is normal (firepower, smoke)

W. Are other commonly used accessories, such as iron clips, iron spoons, iron troughs and copper sheets, in good condition?

Handover requirements:

X the environment of the machine must be clean and tidy, and it must be approved by the successor. If both parties have objections, they should report to the foreman for handling. It is not allowed to make noise on the machine and stop production.

Y. When the successor is not in place on time, the handover personnel shall not negotiate without authorization, but shall report to the cadres for instructions.

Z this kind of products shall be stored in the designated area in accordance with the regulations, neatly placed, and each box of products shall have a work record.

AA。 Before leaving work, the work sheet should be submitted to the quality control personnel and leading cadres for review to confirm the quantity and quality of the products in the class.

BB。 Try not to stay until the next shift. If there is any problem, you should take care of yourself. If this shift can't take care of itself, report to the foreman and get permission before leaving work.

Seven. Matters needing attention for Sunday parking maintenance and start-up:

1. Before stopping the machine, the hammer head should be removed and the zinc liquid on the hammer head should be wiped clean, so that the steel can rotate freely. At the same time, check whether the threaded connection between the hammer head and the hammer handle is in good condition and whether there is welding loss. In general, only 1/3 liquid zinc is allowed to remain in the crucible. Take it out after long-term use, and check whether there are other residual metal objects at the bottom of the crucible. If there is, take it out in time.

2. Remove the mold. If you need to continue using this mold, you need to close the mold and leave a gap of10mm. ..

3. Cut off the power supply, oil supply and gas supply, relieve the pressure of the machine and air compressor, keep the cooling water circulating for 2 hours, and then turn off the power supply of the cooling system.

4. Clean the machine, refuel all lubricating parts, make all travel switches in a free state, and check and maintain all auxiliary equipment related to die casting production, such as lighting, electric fans, carts and hangers.

5. Clean up the working environment, put items, and put all raw materials, zinc slag and waste into storage.

6. Before starting the machine, the water pump and air compressor should check whether the lubricating oil is sufficient and add lubricating oil. Lubricating oil should be 68#. Check the liquid level in the oil tank of the hydraulic system of the machine, start the machine for several cycles, and exhaust the air in the hydraulic system.

7. It is forbidden to heat up to 400 degrees at one time every time the machine is turned on. When the temperature rises to 200 degrees, stop 10- 15 minutes, and then rise above 400 degrees, so as to prevent the crucible from bursting due to uneven cold and heat, and at the same time prolong the life of the burner.

8. The mold must be used to prevent sudden quenching and heating. If hot barbecue is needed, the musket must rotate evenly to expand the barbecue area, so as to avoid concentration, which will cause the cavity to crack and destroy the internal structure of the mold.

9. Hot processing parts, fastening screws, nozzles, goosenecks, etc. Every time when loading and unloading, the zinc slag and other dirt of the machine must be removed, and high temperature oil must be coated before assembly.

10. After the air compressor stops running, before running again, the condensed water in the air storage tank must be discharged, and the lubricating oil should be replaced every three months.

Eight. Basic contents of die casting machine maintenance:

Due to the poor production environment of die casting, there are more zinc flakes and dust on the machine, and the continuous action time is long and the failure rate is high. Therefore, the maintenance of equipment is one of the most important tasks. In order to carry out comprehensive and thorough maintenance of the machine, the following will introduce the maintenance contents of the die casting machine:

1. The major maintenance of the die casting machine should be carried out once every six months, or it must be carried out when the machine stops for a long time.

2. Wipe the machine thoroughly, and put items around the machine for maintenance.

3. Check and record the rotating and moving parts of the machine, and thoroughly rectify the parts that need to be handled.

4. Check whether the hydraulic system around the machine leaks oil and handle it.

5. Check whether the screws in all parts of the machine are effective and abnormal, and handle and replace them.

6. Check the datum plane of the machine and adjust the production management system of the anchor screw die-casting workshop.

7. Check the connecting rod and shaft pin of the machine and ensure that.

8. Check the lubricating oil condition of each part, and clean all lubricating oil holes and pipes.

9. Clean the hydraulic oil filter screen of the hydraulic oil tank, filter the hydraulic oil or whether to replace it with a new one. The hydraulic oil is 46# antiwear hydraulic oil, and the lubricating oil for water pump and air compressor is 68#. The hydraulic oil should be replaced once a year to prevent the hydraulic oil from deterioration, thickening and scaling.

10. Check the nitrogen pressure indicator of the accumulator every three months, and add it in time if it is insufficient. Clean the filter screen and suction head of the cooling tower every three months, and replace the cooling water in the pool.

1 1. Check whether the wiring of all parts of the machine is in good condition, and whether all sheaths and protective covers are in good condition. Whether the accessories of each control panel are complete. Whether the function is in good condition, wipe the control box thoroughly.

12. Check all limit switches, travel switches, indicator lights, changeover switches and related accessories, and repair or replace them.

13. Inspection and confirmation of machine safety.

14. The burner should be cleaned every three months to improve its thermal efficiency.

15. Check the sealing condition of the combustion chamber once a year and repair it in time.

16. Finally, start the trial operation and observe the adjustment. Summarize the maintenance contents. Study the root cause of the failure, find out the preventive measures, and make maintenance records.

Nine: Material Control and Use Specification:

There are many kinds of materials commonly used in die casting production, from the main raw material zinc ingot to auxiliary materials, such as oil, lubricating oil, diesel oil, liquefied gas, industrial salt and so on. As an operator of die casting production, it is necessary to have a basic understanding of these materials in order to facilitate normal production.

1. Use control of zinc ingots:

1. In normal production and use, zinc ingots must be added one at a time, and then twice the weight of one zinc ingot. Each addition shall not exceed two times, so as to avoid the surface quality degradation of molded products due to the sharp drop of furnace temperature.

2. It is forbidden to add metal objects such as copper and iron filings in the charging process, so as to prevent these insoluble metals from entering the charging tank, blocking the flow passage and even damaging the charging tank and hammer, especially iron is almost insoluble in zinc. The formation of metal compounds at high temperature will reduce the fluidity of zinc liquid and the adhesion of electroplating layer, and will also form iron deposits in the crucible. If too many deposits are deposited, the furnace temperature will increase and the thermal efficiency will decrease.

3. Zinc slag is an impermeable substance produced by the melting of zinc ingots and secondary materials in production. It must be pulled to the back of the crucible and fished out frequently, so that the zinc slag will not harden around the charging tank and the hammer head, and prevent it from entering the charging tank, damaging the hammer head or blocking the hammer head, so that the charging tank and the hammer head are scrapped at the same time.

2. Use of oil:

Adding a proper amount of water to the oil is to make the product easy to leave the mold, but it can't be used too much in use, which will cause the mold temperature to be too low, resulting in too many cold lines on the product, which is not easy to polish and electroplate. It is forbidden to wash your hands with oil for personal use.

3. Control over the use of diesel oil and natural gas:

Diesel oil is used as fuel for internal combustion engine, mold cleaning or machine parts cleaning. Diesel oil is flammable, so it should be stored away from fire sources. If there is oil stain on the ground when cleaning the internal combustion engine, it should be dried with sawdust in time. Used diesel oil should be kept in time, and it should not be placed at will to cause combustion. Gas is also used as fuel for combustion and is also explosive. After use, check whether the main brake of the gas storage tank is closed repeatedly.

4. Industrial salt: