How equipment operating instructions are developed. How to write a production manual

/ Production instruction

The production instruction covers the entire cycle of production relations between the employee and the manufactured products or technical work taking place in the organization. Production instructions for each specific specialist are carefully developed taking into account the entire technological process of production or work. And the more complex and dangerous the production, the more documents are used that are involved in the preparation of the production instruction.

All production instructions are universal in nature and do not have model standards. The production instruction does not allow deviations in the description of production and technological processes, since it relies on a large number of clear legislative documents that regulate only certain strictly limited professional actions of employees. The performance of specific actions is reflected in the form of production behavior and is drawn up in production instructions for execution, and is regulated by many documents.

The essence of the production instruction is that it includes detailed instructions and rules for working with stationary mechanisms that have both manual start and installation, and automatic; requirements for the size of the workload for each profession; the level of general vibration; the magnitude of the heat load, taking into account the time of year and the duration of its impact, and other factors of the working environment and related features of the labor process.

So one of the essential criteria reflected in the production instructions is the determination of the severity of labor activity based on the mass of manually lifted and moved weights and the dynamic load on the body during the shift, measured in kilograms - for the category of workers associated with heavy physical labor. The production instruction gives a complete description of the provision of employees with the constitutional right to work in conditions that meet all labor protection requirements, specifying this right (Article (hereinafter referred to as Art.) 219 of the Labor Code of the Russian Federation (hereinafter referred to as the Labor Code of the Russian Federation)).

The state simultaneously establishes guarantees for employees (Article 220 of the Labor Code of the Russian Federation) and imposes on the employer the obligation to ensure safe conditions and labor protection for employees (Article 212 of the Labor Code of the Russian Federation), and also provides for the need for state supervision and control over compliance with labor protection requirements and establishes the responsibility of persons guilty of violating labor protection requirements (Article 419 of the Labor Code of the Russian Federation). These data are written in the production instructions. The production instruction also reflects the minimum standards for providing workers with personal protective equipment that are mandatory for the employer, that is, it provides for the rules for providing workers with special clothing, footwear and other personal protective equipment. This norm in the production instructions looks like necessary prescriptions for the conditions of safe work of workers, which should not be violated by either the employee or the employer.

How to write a production manual

To create a production instruction, it is necessary to study and describe in detail the production or technological processes. It can also describe physical, chemical phenomena, equipment operation rules or adjustment work. The compiler of the instructions has a great responsibility and he needs to delve into the production process in detail.

You will need

sample instructions

safety requirements

Instruction

1 Write an introductory part of the production instruction. Here reflect the scope and purpose of the document.

2 Reflect the requirements for labor safety in the main part of the document, before the job description. Here you can indicate links to available labor protection instructions, sanitary norms and rules, or compose the text of specific requirements. Here also indicate the personal protective equipment used, safety requirements for components, assembly units and materials.

3 Describe the technological sequence of actions, operations. Describe the processes in simple phrases denoting the action on the object, accompanied by an indication of the parameters (if necessary). Write down information about the required process mode, i.e. parameters of temperature, pressure, power, etc., required during the operation.

4 Specify what equipment is involved in the technological process. Specify the names of fixtures, tools and measuring instruments in accordance with the technological documentation for them. By assigning a letter code to tools and fixtures, you can shorten the text of the description of operations.

5 Make a description of the operation of the equipment in the form of a list or sequence of actions of the personnel serving it. There may be clauses about the duties of personnel during the preparation of equipment for operation, during its operation, breakdowns and emergencies, as well as upon completion of work on the equipment. In addition, the responsibility of personnel in the maintenance of mechanisms and work on them is mandatory.

6 Break large text into sections and subsections. Number paragraphs and subparagraphs. Provide tables or graphic illustrations, if necessary.

7 On the first sheet of the instruction, indicate its name (above), the industry to which the production belongs. Below on the right there should be a signature on the approval of the instruction, the position and date of the approver. Next, place the main text of the instruction, which, if necessary, transfer to subsequent pages. On the right and below, in a separate field, indicate the composition of its performers and the last name, name of the developer and controller.
POSITION

on the development of Production Instructions

Introduction
This Regulation has been developed on the basis of the requirements of the Unified System for Technological Documentation (ESTD), ECTS, GOST 12.0.004 and taking into account the letter of the Federal Service for Labor and Employment dated November 24, 2008 N 6234-TZ « On job and work instructions” and determines the procedure for the development, approval and application of production instructions for working professions of LLC “” (hereinafter referred to as the organization).
1. General Provisions
1.1. Production instruction- This is an organizational and legal document that defines the main functions, duties, rights and responsibilities of an employee in the exercise of his activities in a particular profession.

Production instruction- this is a document that determines the procedure for personnel to operate any equipment: acceptance and delivery of a shift (if necessary), start-up, switching on, shutdown, withdrawal for repair, actions in case of accidents, etc.

1.2. Production instructions for employees of each structural unit are developed by the head of the structural unit on the basis of the "Regulations on the structural unit". Job descriptions should be specific and actually describe jobs.

1.3. Production instructions are reviewed in a unified manner in accordance with changes in the structure and staffing of the Organization, as well as after certification.

1.4. The meaning of the production instruction as an organizational document is as follows:

Secures the legal status and place of the employee in the management system;

Defines the tasks, functions, rights and obligations of the employee;

Allows you to reasonably evaluate the results of activities;

It is the legal basis for the certification of an employee, determining his disciplinary and material liability;

Establishes organizational bases of legal activity.

1.5. Production instructions are reviewed once every 5 years.

1.6. The retention period of production instructions in the Organization is 45 years after they are replaced.

1.7. The storage of the originals of production instructions is carried out by the person responsible for the personnel work of the Organization. If necessary, certified copies can be kept by the heads of structural units and used in the current work of structural units.
2. The procedure for the development and execution of production instructions
2.1. Production instructions are developed on the basis of the organization's staffing table, the All-Russian classifier of workers' professions, positions of employees and tariff categories OK 016-94 (OKPDTR), instructions for the operation of manufacturers for equipment, tools and fixtures used at the workplace of a worker of a particular profession by the head of a structural unit who is responsible for the workplace.

2.2. Before developing production instructions, it is necessary to carry out:

Study of the technological (production) process, identification of potential hazardous and harmful production factors that arise during its normal course and in case of deviations;

Determination of safe methods and techniques of work, their sequence, as well as

technical and organizational measures to be included in the instruction;

Determination of compliance with the safety requirements of the equipment used,

devices and tools;

The study of the design features and effectiveness of protective equipment that

can be used in the performance of relevant work.

2.3. The requirements of the instruction must be set out in accordance with the sequence of the technological (production) process, taking into account the types of equipment, fixtures, and tools.

2.4. The text of the instruction should include only those requirements that relate to the safety of a particular type of work and are carried out by the workers themselves.

2.5. Production instructions for workers should not contain any references to other normative and normative-technical documents (except for references to other instructions for workers). The main requirements of these documents should be taken into account by the developers of the instruction. If necessary, the requirements of these documents should be included in the instructions.

2.6. The requirements of the instruction must be concise and clear, taking into account the specific conditions and specifics of the work performed, and not allow for various interpretations. The terms used in the instructions must comply with the terminology adopted in the regulatory documents. When using terms that are not established in these documents, the texts of the instructions should provide their definitions or explanations for them.

Replacing words in the text of the instruction with letter abbreviations (abbreviations) is allowed provided that the abbreviation is fully deciphered when it is first used.

2.7. The instructions should not use colloquial expressions, as well as professional and technical colloquial terms.

The text should avoid expressing the requirements in the form of a ban, and if this is not possible, explain the reason for the ban. Individual points of the instruction should not be reinforced with the words “categorically”, “especially”, “strictly obligatory”, “unconditionally”, etc., since all points of the instruction are equally important and mandatory. Separate provisions of the instruction can be illustrated with drawings, diagrams, photographs explaining the meaning of these requirements.

The form of the statement of requirements should be prescriptive: make, turn, move, register, etc.

2.8. The instructions must include requirements that can be met by the workers themselves and do not contain organizational and technical requirements, the fulfillment of which is not necessary to ensure the safe performance of work and the creation of normal sanitary conditions at the workplace.

2.9. The instructions should not include the duties of the heads of the unit, because their knowledge is superfluous for the worker.

2.10. The instructions must set out the procedure and requirements to ensure the safe conduct of work. If the safety of the work is due to certain standards, then they must be indicated (the size of the gaps, distances, height, voltage, concentration, etc.).

2.11. The text of the instruction should be divided into sections (if necessary, into subsections) and paragraphs and numbered in Arabic numerals: sections - within the instructions, subsections - within the section, paragraphs within the subsections (in their absence - within the sections).

Since the "Introduction" does not carry instructional instructions, it is possible not to carry out numbering inside it.

2.12. The name of the instruction should indicate the type of profession for which it is intended. The developed draft instruction, with a list of used normative and technical documentation, should be sent for consideration to the interested services and structural divisions. After reviewing and summarizing the comments and suggestions, a final draft instruction for employees is developed.

2.13. All instructions are assigned a number (letter abbreviation - designation of the type of instruction, Arabic numerals - subdivision number (if necessary), serial number according to the List, year of development)

For example: PI 01.01-2012 - Production instruction for ________ ( profession name)

2.14. Production instructions must be executed in the form given in Appendix 1
3. Content and writing of the Production Instruction
3.1. The content of the Production Instruction depends on the work performed by the worker, the workplace, the composition of equipment, tools and fixtures and must correspond to the qualification characteristics of the professions, types of work included in the worker's responsibility.

3.2. Approximate content of sections of the Production Instructions:

Introduction

1. General Provisions

2. Characteristics of works

4. Responsibility

5. Description of the workplace and types of equipment in use

6. Description of the operation of equipment, mechanisms, tools and devices.

6.1. Definition and purpose

6.2. Technical specifications

6.3. Description of the production process

6.4. Conditions for conducting the production process and (or) operating equipment, mechanisms, tools and devices

6.5. Preparation for repair

6.6. Current service

6.7. Production Problems and Solutions

7. A list of local regulatory documents, the requirements of which the worker must know and comply with.

The title and content of the sections of the Production Instruction may be changed depending on the specific conditions of the workplace and the work performed.

3.3. In the "Introduction" section

3.4. In the section "General provisions" should be reflected:

Full name of the profession (exact name in accordance with the staff list, indicating the category of employee in accordance with the All-Russian Classifier of Occupations of Workers, Positions of Employees and Wage Categories;

In whose direct subordination is the employee (in addition, to whom is he subordinate for the period of absence of a superior person);

The procedure for hiring and dismissal, on the proposal of which person the hiring is carried out, with which official the appointment is agreed;

How the work is organized - independently by the employee, in accordance with the work plan of the structural unit or according to the flexible or other work schedule approved by the Director of the Organization;

Has an irregular working day been established for the employee, if his profession is included in the list of positions, specialties and professions with irregular working hours approved by the order of the Director of the Organization;

Whose oral and written orders are carried out by the employee - in addition to the orders of the immediate supervisor or in his absence;

Qualification requirements for education, work experience - are developed on the basis of ECTS;

What an employee should know.

3.5. The sections "Characteristics of work", "Rights", "Responsibility" should reflect the requirements determined by the ECTS for this profession and additionally prescribed specific types of work determined by the employer that are not included in the ECTS, but necessary for the production activities of the organization's division (combination of professions, special types jobs requiring additional training, etc.).

3.6. In the Section "Description of the workplace and types of equipment operated"

A brief description of the workplace is given with the definition of specific boundaries or an indication of the sections of the subdivision or territory where the worker performs work, the types of equipment, the mechanisms used, tools and devices that serve and are used by the worker in the performance of the work performed in accordance with the Section "Characteristics of work".

3.7. In the Section "Description of the operation of equipment, mechanisms, tools and devices"

Taking into account the requirements of the Manuals or Instructions for the operation of equipment, mechanisms, tools and fixtures from manufacturers, the Rules for the Design and Safe Operation and specific operating conditions determined by the organization, the following are described:

Definition and purpose of operated and used equipment, mechanisms, tools and devices or references are made to other local regulatory documents that determine the procedure for the safe operation of specific mechanisms, tools and devices;

The technical characteristics of the operated equipment, mechanisms, tools and fixtures included in the service facility at the worker's workplace are indicated from specific Manuals or Instructions for the operation of equipment, mechanisms, tools and fixtures from manufacturers;

The description of the production process is made with the indication of the necessary parameters for conducting the process, interaction with other production processes or the actions of other workers;

The conditions for conducting the production process and (or) operating equipment, mechanisms, tools and devices are determined by the requirements of the Manuals or Instructions for the operation of equipment, mechanisms, tools and devices of manufacturers, the Rules for the Device and Safe Operation and specific operating conditions determined by the organization;

When preparing for the repair of equipment, the procedure for shutting down the equipment (de-energizing, disconnecting, disconnecting, etc.), freeing the equipment from products and oils, etc. is determined. actions;

During the Routine maintenance of equipment, mechanisms, tools and fixtures, the procedure for inspection, lubrication, care is determined, the terms of service, lubrication maps, etc. are determined. operations;

Production failures and methods for their elimination are usually drawn up in the form of a table in accordance with the recommendations of the Manuals or Instructions for the operation of the equipment of the manufacturers and the specific operating conditions determined by the organization.

3.8. In the Section “List of local regulatory documents, the requirements of which the worker must know and comply with”, reference is made to specific Instructions on labor protection by profession, Instructions on labor protection and safe operation and other types of Instructions, the requirements of which the worker must know and comply with when performing work in accordance with this production instruction

In general, there is no generally accepted definition of the term Production instruction. Everyone defines it to the extent of their depravity or awareness.

Rather, it is a collective image.

So I came to the conclusion that every engineer or other high-ranking person from HSE comes up with the rules for maintaining documentation. We have, in principle, a standard for PB OT and OS, but it is also correctly defined in terms of the specific content and number of instructions. Is there a list recommended OT magazines by departments. Also exists too recommended the list concerning the technical documentation - there is nothing concrete in it either. Based on all this, for some reason, OT believes that from the quantity recommended should be at least twice as many instructions and logs:80: . I agree that it is necessary to register EVERYTHING, to acquaint under the signature: shock:. So that later you could say, but we warned you ... we told you about it .... and you: fool: - and responsibility is removed from us == FULL NON-FUNCTION== Such an amount of information a person is simply not able to "absorb" is not real !

I think sensible instructions should be brief - summarized and relating only to the narrow concrete activity of the worker. Masters, mechanics should conduct repeated - short briefings directly on the type of daily activity and the main duties of their personnel of the brigade or service. But all kinds of classes, meetings - an hour of safety, conversations on the lessons learned from incidents, additional training in civil defense and emergency situations and everything that indirectly concerns workers and for full compliance they should be familiarized - should be handled by health and safety specialists.

At the direction of OT, we already made a list of instructions, the instructions themselves, indicated the points of the instructions during the briefings (seemingly so competently !!!) ................ The "auditor" arrived and asked senior master: How many people are in your unit???... how long does it take for everyone to be instructed??? === and when are you engaged in production???......!!! :unknw: .......... The authorities are changing new lists in a different way we are writing down a bunch of paper again .... The "Senior Auditor" arrives = everything is changing again - this should be excluded ......, here add........, this is the input..... but this is the output....... It turns out infinity!

Per indication ofOST 64-02-003-2002 thanks! but he on the approval of technological regulations for the production of medicines and their intermediates ... and we are, as it were, more towards the machine-building and oil industries. If you refer to it, they can say that it is not about us.................. Maybe there is something (from the OSTs) in more detail!?

1.1. To perform the duties of a locksmith for the repair and maintenance of hoisting machines, persons are allowed not younger than 18 years old, who have passed a medical examination, trained in the appropriate program, who have passed introductory and workplace safety briefings.

1.2. The admission to the work of a locksmith for the repair and maintenance of lifting machines is issued by order of the enterprise after the issuance of a certificate and this instruction.

1.3. Re-testing the locksmith's knowledge is carried out by the commission:

periodically, at least once every 12 months;

when moving from one enterprise to another;

at the request of the person responsible for supervision, or the inspector of Gosgortekhnadzor.

A locksmith admitted to independent work on the repair and maintenance of hoisting machines must know:

• production instructions;
• labor protection instructions;
• purpose, arrangement and principle of operation of all mechanisms of the serviced equipment and instructions for maintenance and repair;
• know the main sources of danger, including mechanical, electrical, hydraulic, as well as put into practice methods of protection against them;
• know and be able to identify the main defects and damages of metal structures, mechanisms, limiters, indicators, recorders and control systems of the substation by visual-measuring control;
• know and be able to perform commissioning work on the substation;
• be able to apply in practice the technology of repair and restoration of components and parts of the substation;
• to know and be able to use rigging and mounting devices, lifting mechanisms, slings corresponding in terms of carrying capacity to the masses of the mounted (dismantled) elements for the installation (dismantling) of the substation;
• be able to apply the established procedure for the exchange of conditional signals between the employee supervising the installation (dismantling) and the rest of the personnel involved in the installation (dismantling) of the substation. Comply with the practical requirement that all signals during the installation (dismantling) are given by only one employee (foreman of the installation team, link, rigger-slinger), except for the “Stop” signal, which can be given by any employee who has noticed the danger;
• have documents confirming the passage, in the prescribed manner, of vocational training in the relevant types of activities of working specialties;
• know the basic schemes for slinging loads (when performing the duties of a slinger) and methods for testing PS;
• know and comply with the requirements of operational documents;
• the main causes of malfunctions and accidents in mechanisms, to be able to find and eliminate them;
• technological process of repair, assembly and installation of mechanical equipment;
• methods and techniques for performing plumbing and installation work;
• purpose, device, design, rules for the selection and use of working, measuring and fitter's tools, their handling and storage rules;
• range and purpose of lubricants used for lubrication of mechanical equipment;
• methods of providing first aid to the victims, the location of the first-aid kit;
• fire warning signals, the location of fire extinguishing equipment and be able to use them.

1.5. When using hoisting machines controlled from the floor for repair purposes, the repairman must undergo a special briefing, followed by a test of skills in driving the machine and tying (hooking) the goods in the prescribed manner.

1.6. All accidents and accidents must be reported to the person responsible for the work.

1.7. Upon receipt of a new (unfamiliar) work, the locksmith must require additional instruction from the master.

1.8. During work, you must be attentive, not be distracted by extraneous matters and conversations, and not distract others.

1.9. During work, you should follow the regime of work and rest. Rest and smoke are allowed in specially designated areas.

1.10. During work, the locksmith may be exposed to the following hazardous and harmful production factors: industrial microclimate, noise and vibration from working mechanisms, vapors of fuels and lubricants.

1.11. Locksmiths must be provided with overalls: a cotton suit, canvas mittens. For outdoor work in winter, additionally: a cotton jacket with an insulated lining.

1.12. It is not allowed to turn on or stop (except in emergency cases) machines, machine tools, mechanisms and electrical appliances, work on which you have not been entrusted with by the administration.

1.13. It is not allowed to touch general lighting fittings, broken electrical wires, terminals and other live parts, open the doors of electrical distribution cabinets and remove guards and protective covers from live parts of the equipment.

1.14. If the electrical equipment is faulty, an electrician should be called. You are not allowed to troubleshoot yourself.

1.15. In the event of an electric shock to a person, it is necessary to quickly turn off the part of the equipment that the victim touches. If at the same time the victim may fall from a height, it is necessary to prevent or secure his fall. If it is impossible to quickly turn off the equipment, it is necessary to separate the victim from live parts.

1.16. At voltages up to 1000 V, a dry rag, board, rope, clothing or other dry, non-conductive material should be used to separate the victim from live parts. Use of metal, wet objects is not allowed. If necessary, cut or cut the wires (each separately) with an ax with a dry wooden handle or a tool with insulated handles.

1.17. Persons who do not comply with the requirements of this Instruction are subject to administrative or criminal liability.

Production instruction for a locksmith

2. Safety requirements before starting work

2.1. Before starting work, it is necessary to put the work clothes in order: fasten the cuffs of the sleeves, tuck in the clothes so that there are no developing ends, put the hair under a tight-fitting headdress. It is not allowed to work in light shoes (slippers, sandals, sandals).

2.2. Carefully inspect the place of work, put it in order, remove all foreign objects that interfere with the work.

2.3. Check the availability and serviceability of tools, fixtures. When working, use only serviceable tools:

wrenches must match the size of the nuts and bolt heads and not have cracks and nicks; the jaws of the keys must be strictly parallel and not rolled up, the sliding keys must not be loosened in the moving parts; laying pads between the jaws of the keys and the head of the bolt, as well as lengthening the handles of the keys with the help of pipes and bolts or other objects is not allowed;

metalwork hammers and sledgehammers must have a slightly convex, not oblique and not knocked down, without cracks, the surface of the striker, must be securely fastened to the handle by wedging with pointed wedges, must not have hardening;

the handles of hammers and sledgehammers must have a smooth surface and be made of hardwood (dogwood, beech, young oak, etc.);

percussion instruments (chisels, cross cutters, barbs, punches, center punches, etc.) must not have cracks, burrs, work hardening. The chisels must be at least 150 mm long.

2.4. It is allowed to carry the tool to the workplace only in a special bag or box.

2.5. Check the lighting of the workplace so that it is sufficient and does not blind the eyes. When working, use local lighting with a voltage not exceeding 36 V.

2.6. When using an electric lamp, you should check the presence of a protective grid on the lamp, the serviceability of the cord and the insulating rubber tube. The voltage of a portable lamp is allowed no higher than 12 V.

2.7. If necessary, work with lifting machines controlled from the floor, check the serviceability of the main parts and assemblies of the load lifting mechanism, namely:

the condition of the hook, the absence of wear in its mouth more than 10% of the original section, the absence of cracks, straightness, jamming in the hook cage and the presence of a cotter pin or locking of the hook fastening nut in the cage;

the condition of the cargo rope (the number of broken wires at one step of the rope lay should not exceed the established norms);

the operation of the brake of the load lifting mechanism (checked by a load equal in mass or close to the nominal load capacity of this machine when lifting it to a height of 200-300 mm; when stopping at a specified height, the brake must securely hold the load; when the load slips or sags, the brake must be adjusted or replaced) ;

the operation of the hook lifting height limiter (when lifting the hook up, it should stop after pressing the limit switch);

the operation of the push-button control (all movements must correspond to the inscriptions above the buttons), the absence of jamming of the buttons in the sockets and the state of visible protective grounding (cable).

Note: To work with a hand hoist, you must obtain the permission of the person responsible for the good condition of lifting machines.

2.8. Cleaning, repair, inspection of the crane in operation and its parts should be carried out only after it has been stopped and disconnected from the power supply.

2.9. Work near the moving parts of machines and mechanisms is allowed after the fencing of dangerous places.

Production instruction for a locksmith

3. Safety requirements during work

3.1. Only the work assigned by the administration should be performed.

3.2. Cleaning material used in the process of work should be collected in specially installed metal boxes with lids.

3.3. It is not allowed to store flammable materials and cleaning oily material in the workplace.

3.4. When pressing or pressing parts with a sledgehammer and a punch, the latter should be held with tongs or a special grip. The punch should be made of soft material.

3.5. When cutting metal with a chisel, it is necessary to use safety glasses with safety glasses or mesh. Protective shields should be installed to protect others.

3.6. When working with a stacker, the second end should be closed with a special case or handle.

3.7. When working with a blowtorch, it is not allowed:

use a flammable liquid that is not intended for this lamp;

pour fuel into a burning lamp;

pour fuel near an open flame;

pump more air into the lamp than the allowable pressure;

fill more than 3/4 of the lamp capacity with fuel.

If a malfunction is detected (fuel leaks, gas leaks through the burner thread, etc.), stop work immediately and replace the blowtorch.

3.8. When working with power tools, the following requirements must be observed:

work in rubber gloves and dielectric galoshes or on a dielectric rug;

do not connect the power tool to switchgear if there is no reliable plug connection;

protect the wire supplying the power tool from mechanical damage;

do not carry the power tool by the wire, use a handle for this;

do not replace the cutting tool until it stops completely;

during interruptions in work or a power outage, turn off the tool;

do not work with portable power tools at a height of more than 2.5 m on ladders.

3.9. When carrying out periodic inspections of hoisting machines, a thorough check of the condition of all mechanisms, cargo ropes, hook suspension, and metal structures should be carried out. The results of the inspection and the defects identified during the inspection should be recorded in the journal of periodic inspections of hoisting machines.

3.10. When inspecting the crane mechanisms, you should:

check the snap fastening of the couplings connecting the shafts of electric motors, gearboxes, etc.; if a backlash is detected, eliminate it; when the keys are worn, replace them;

if a loosening of the bolted connection of the coupling halves is detected, tighten the loose nuts; in case of wear of leather or rubber rings at the fingers of elastic couplings, put new rings;

prevent longitudinal movement of the worm in the thrust bearing, causing shocks when starting and stopping the electric motor;

do not allow the outer rings of ball bearings to rotate into the bearing housing and ensure that the inner fingers fit snugly on the shaft journal;

upon detection of a tooth fracture of any gear of the lifting mechanism, a crack in the rotating parts of the crane mechanisms (gear wheels, blocks, brake pulley, clutch, etc.), stop the operation of the crane until the defective part is replaced and inform the master about it;

when trying the electric brake, make sure that there is at least a small margin of the electromagnet thrust, and also that the counterweights are firmly fixed on the brake levers (if necessary, they should be strengthened with a chain); when weakening the brake rods, periodically, depending on the wear of the linings, tighten the rods;

if even small cracks or tears are found in the brake band, stop the operation of the crane, informing the master about it;

in case of significant wear of the lining at the brake pads, change the worn linings;

periodically, at least once a quarter, check the fastening of the leveling fixed block, as well as the condition of its axis;

make sure that all accessible rotating parts of the lifting machine mechanisms, such as gears, shafts, ratchets, sprockets, keys, etc., are covered with guards of an appropriate design;

monitor the timely lubrication of all crane mechanisms and the absence of grease leakage from bearings and gearboxes;

regularly inspect the crane truss and trolley frame.

3.11. Repairs to the crane may only be started with the permission of the responsible person.

3.12. Repair of the crane should be carried out only at repair sites. Before starting work, the crane must be de-energized by turning off the breaker of the main trolley wires and supplying short circuits. In addition, turn off the switch in the crane cabin. Prohibiting posters should be hung on the switches: “Do not turn on! People are working.”

3.13. Trial switching on of the crane during repair and at the end of it is allowed to be carried out only with the permission and in the presence of the person responsible for the repair.

3.14. Upon completion of repair or maintenance, an appropriate entry must be made in the journal of periodic inspections of the crane.

3.15. Before installing a grinding wheel on the machine, you must make sure that it has a factory mark on it, which must indicate the maximum allowable number of revolutions. It is not allowed to exceed the maximum permissible number of revolutions. It is not allowed to work on grinding wheels that have cracks or other defects.

3.16. The following precautions should be observed when mounting and attaching the grinding wheel to the spindle:

do not allow strikes in a circle;

use clamping discs (flanges) of the same size;

install special spacers at least 1 mm thick between the clamping disks and the stone;

make sure that the diameter of the hole in the stone is 0.51 mm larger than the spindle diameter.

3.17. After installing the grinding wheel, you must:

check the operation of the grinding wheel at idle for 2-3 minutes and make sure that there is no stone runout and that the grinding wheel is properly balanced;

strengthen protective covers;

check that the circle starts rotating smoothly, without jerks.

3.18. The gap between the grinding wheel and the handpiece should be no more than 3 mm.

3.19. When working on grinding machines it is not allowed:

clean the circle, touch it with your hands;

open the protective covers of the shaft, spindle, pulley, stone;

put on, take off and transfer the belt;

work without a protective screen or glasses;

work with the end surfaces of the circle, if it is not intended for this type of work.

3.20. When working, it is necessary to ensure that the circle is worked evenly. In the formation of potholes and ledges, the circle should be replaced.

Production instruction for a locksmith

4. Safety requirements in emergency situations

4.1. If a malfunction of an electrified, pneumatic or other tool is detected, it is necessary to disconnect it from the mains and report this to the foreman or mechanic.

4.2. In case of accidents, provide the victim with first aid, if necessary, send the victim to a medical institution.

In case of injury, immediately stop work, notify the administration and seek medical attention.

4.3. When captured by rotating parts of machines, slings, traverses, hooks, etc. parts of the body or clothing must be immediately signaled to stop work. You should not try to free yourself from the grip if it is possible to attract others.

4.4. In the event of a fire, you must:

stop working;

turn off electrical equipment;

notify management and call the fire brigade;

start extinguishing the fire with the available fire extinguishing equipment.

5. Safety requirements at the end of work

5.1. Tidy up the workplace, put the tools and fixtures in the tool box.

5.2. Inform the shift worker, foreman or foreman about the work performed, the existing malfunctions, the measures taken and their elimination, and make an appropriate entry in the shift mechanics log.

5.3. Wash hands and face with warm soapy water and shower if possible.

5.4. Hang overalls in a locker specially designed for this purpose.

6. Responsibility.

A mechanic for the repair and maintenance of cranes, trained and certified in the prescribed manner, having a production instruction in hand, is responsible for violation of the requirements of this instruction in accordance with the current legislation of the Russian Federation.