In many modern manufacturing firms, production instructions are issued to optimize the interaction between employees and management. They are considered as local normative sources having the same legal force, in particular, with employment contracts. What is the specificity of the corresponding instructions? How are they developed?
What is a production instruction?
A production instruction is usually understood as a local legal act, which regulates the labor function of an employee, determines the list of his duties, rights, as well as the conditions for liability for certain actions. It can be noted that labor protection at an enterprise involves the compilation by company employees responsible for personnel management, along with the document in question, also sources such as fire safety instructions, labor protection instructions.
All types of marked sources are compiled in accordance with the legislation of the Russian Federation, as well as in accordance with the established specific enterprise internal corporate standards. Occupational safety at the enterprise is a process that requires the most great attention development of the types of documents under consideration.
In the production instruction, the norms characterizing a specific position in the company are fixed. So, it reflects the rules that establish what work the employee is obliged to perform, the requirements for the skill level of the employee.
Let us consider in more detail the features of the use of the documents in question.
Purpose of production instructions
Why does a company need a production manual? Purpose this document, if you follow the norms of official sources of law and practice corporate governance, is to ensure the regulatory regulation of personnel management in the company. The production instruction regulates:
- key issues of personnel management;
- interaction of employees of various profiles with colleagues and management;
- order of execution by specific specialists labor functions.
Creating high-quality production instructions allows the company to:
- line up effective system division of labor in the organization;
- stimulate labor productivity;
- provide control over the activities individual workers or their groups;
- increase the level of responsibility of the company's employees for their own actions in the process of solving problems related to business development.
The presence of production instructions in the internal corporate document management system allows the company to accelerate the process of adaptation of new employees to the specifics of local production tasks. This contributes to the stability of the process of production of goods, the provision of services, stimulates business growth and the development of new promising segments.
The relationship of the production instruction with other internal corporate sources
The document in question is quite closely related to other local regulations that are issued at the enterprise. First of all, it should be noted that the production instruction is a source that can be divided into a number of categories. Which ones?
There are sources such as the fire safety production instruction. In her Special attention paid, thus, the rules for the response of employees to the occurrence of a fire threat. It may supplement the main production instruction or be published as a separate local source.
There are instructions for industrial sanitation. They fix the rules that reflect how employees should act in order to maintain the required level of sanitary conditions for the implementation labor activity. This document, again, can supplement the main one or be published as an independent local source.
In some cases, the source in question, can regulate labor functions not by positions, but by areas of activity of specialists. For example, production instructions for the operation of electrical installations can be drawn up. There are documents of a similar purpose related to other areas of labor protection - not directly related to the labor functions of employees of enterprises. So there are production and technical instructions, which in their structure can be close to the manuals for the operation of certain fixed assets used in production.
The document in question is developed for each position by specialists of the company's personnel department. For this, a typical production instruction for a particular position, as well as various sources of law, can be used. For example - Qualification guide, approved by the Ministry of Labor of the Russian Federation in Decree No. 37, issued on August 21, 1998. Often used for these purposes and industry sources of law, recommendations of experts and analysts.
Which source should be used to develop the optimal job description depends on the size of the enterprise, the types of products manufactured, and the characteristics of the organization. production process. Also, the requirements for relevant documents that are put forward by the parent organization, the owners of the company, and investors may also matter.
Production instruction as a source of regulation of the technological process and an employment contract
The production instruction is linked to the employee's employment contract. In some cases, their provisions are duplicated or mutually supplemented. In many firms, HR specialists prefer to include as much as possible of the norms characterizing the production instruction, namely, in the employment contract. This is due to their desire to minimize labor costs for document circulation: the fewer sources of local norms, the easier it is to organize their accounting.
But this is not always effective. The fact is that in a number of cases it is necessary to include a description of the technological process in the production instructions, while it is sometimes problematic to place the appropriate wording in the labor contract. The technological process is one of the main criteria for distinguishing a production instruction from other types of local sources of norms. In order for an employee of the company to correctly ensure that his work complies with the noted criterion, the employer must provide him with the opportunity to familiarize himself with the official source of requirements for his labor function.
If the instructions in question are separate sources, contracts concluded by the company with employees under the Labor Code of the Russian Federation usually indicate a link to them. It can be noted that both the production instruction and the employment contract have the same legal force from the point of view of the law. If an employee violates the rules that he undertook to comply with the instructions - including those that characterize the technological process, then the same legal consequences may appear that arise if the provisions of the contract are not observed.
Production and job descriptions
So, the production instruction can be used in the company along with other sources on labor protection. Some of them are similar to it, complement it. In particular, the production instruction is very similar to the job description.
In some cases, it is legitimate to consider them as synonyms. To draw up a job description, the same sources of law as noted above can be used. But, in fact, the production instruction characterizes mainly work positions, and therefore is most often drawn up by personnel services. industrial enterprises. In the relevant document, a significant place is occupied by the description of the technological process that the employee of the company must follow as part of the performance of his own labor function.
That is, the scope of the document under consideration is narrower. The production instruction regulates labor activity in industrial firms. In turn, the publication of documents of the second type is more typical for service enterprises. But from the point of view of the structure, both will be almost the same.
Production instruction structure
Thus, we will study in what structure a typical production instruction can be presented. The document in question most often consists of the following key sections:
- "General Provisions".
- « Qualifications».
- "Production Functions".
- "Responsibilities".
- "Rights".
- "Responsibility".
In some cases, the production instruction is supplemented by other sections - for example, regulating the procedure for rewarding an employee for outstanding achievements in work.
The specified structure of the document, in general, is applicable to the job description. The main distinguishing criterion between the corresponding types of documents, as we noted above, is the scope.
The procedure for developing production instructions is usually approved by the local regulations of the employing company, since such sources of law are not accepted at the official level in the Russian Federation. Let's study the procedure for developing the source in question in more detail.
Features of the development of production instructions
First of all, you can study the question: in connection with what does the enterprise need to develop a production instruction? As a rule, such a need becomes relevant:
- when the company forms an additional staff of employees (for example, in connection with the expansion of production, the opening of new branches);
- with a significant change in the labor function, which is regulated by local norms adopted earlier;
- when content changes employment contracts with employees for one reason or another (for example, during the modernization of production).
A production instruction is a document that can be recommended for development in a company on the recommendation of a higher structure, experts, audit companies. The source in question can be formalized as an independent source or approved as an annex to the employee's contract. In Russian firms, the main types of documents used in the labor protection system (industrial, job descriptions in particular) are developed using both methods.
But, in general, both procedures are characterized by similar stages. Let's study them in more detail.
First of all, HR specialists work out the text content of the document. For this, as we noted above, a standard production instruction, as well as official sources of law, can be used.
The section of the document that reflects it general provisions, as a rule, does not cause difficulties in design. This part of the instruction is one of those that are characterized by minimal differences when comparing documents developed for different positions or groups of labor functions.
Certain nuances characterize the design of the "Qualification Requirements" section. They are most often seen in the context of:
- official duties;
- necessary knowledge of the employee;
- level of education of a specialist and other qualification criteria.
If a standard production instruction is used in the process of creating a document, then the wording that is present in it can quite superficially regulate the specifics of labor functions at a particular enterprise. Due to this personnel service the company may need to supplement the relevant standards with those that more effectively reflect the characteristics of the production process in the company. To solve this problem, the help of experts and analysts can be involved.
The next key section of the document is "Production Functions". It is necessary to pay special attention to its compilation: as a rule, it is precisely for it that the norms are characteristic that reflect the specifics of the regulation of a particular labor function.
For example, production instructions for the operation of electrical installations may regulate functions that are very different from those that characterize the work of, for example, a locksmith. This may be due to the specifics of the equipment used by the specialist of the profile for which the document is being compiled. The locksmith's production instruction will include norms that regulate another labor function in more detail.
The "Responsibilities" section of the instruction is also among those that include wording that reflects the specifics of a particular position in the enterprise. For a specialist in the maintenance of sanitary equipment, the duties will be one, for a worker - others. For example, plumbers are characterized by the functions of ensuring the proper operation of heating systems, water supply, and timely repair of the relevant infrastructure. In turn, the worker can be responsible for the correct installation of these systems, checking their initial performance.
Sections such as "Rights" and "Responsibility", in turn, may include sufficiently universal language. The production instruction of a worker, a locksmith, a specialist in electrical installations may have practically similar norms in terms of the marked sections of the document in question.
The next step in creating a production instruction is layout. Let's study its features in more detail.
Features of the design of production instructions
When solving the corresponding problem, one can focus on official sources of law - such as, for example, GOST R 6.30-2003. This GOST regulates the procedure for creating internal corporate administrative documentation at enterprises. The main requirements contained in the relevant
All work at production facilities must be carried out in compliance with the rules industrial safety. The enterprises develop special documents that describe the procedure for carrying out technological processes and the duties of the personnel performing them.
This document is production instructions, the content of which is established by the Federal Norms and Rules (FNP).
For which objects is the development of production instructions mandatory?
Production instructions are developed at enterprises engaged in construction (meaning both the construction of an object and its reconstruction, conservation, technical re-equipment, operation or liquidation) of such objects as:
- HPF (hazardous production facilities).
- Power industry.
- Operating electrical, thermal installations or networks, as well as hydraulic structures.
- Manufacturing or repairing (including installation, adjustment, maintenance work):
- technological equipment used at hazardous facilities;
- vehicles transporting hazardous substances.
When developing production instructions, consider:
- qualification requirements (sources - directories, standards, etc.);
- features of technological processes of production.
Instructions are intended for workers, are stored at enterprises at workplaces and can be issued to an employee against signature.
For staff, knowledge of production instructions is a must!
Checking knowledge of production instructions
Certification of employees, during which knowledge is tested on:
- general industrial safety requirements;
- special issues that relate to the competence of the employee;
- energy security requirements;
- safety requirements of hydraulic structures -
carried out before the admission of employees to independent work on the object.
Contents of the production instruction
The text of the production instruction may differ at each specific enterprise, depending on its specifics, type of work, technological processes, etc.
- General information.
- Passing instruction, testing knowledge.
- Communication with other workplaces.
- Duties of the employee, as well as his rights and responsibilities.
- Notes on the acceptance and delivery of the shift.
- Description of the specific workplace, equipment installed, materials used.
- Technological scheme of the technological process.
- Records of equipment start and stop.
- Possible deviations from the normal course of the technological process, methods for solving problems.
- Equipment emergency stop marks.
- Rules for safe work.
The text part of the instruction may be accompanied by diagrams and drawings, for example, technological diagrams, etc.
The document is approved by the head of the enterprise or organization responsible for the operation of the facility.
17.1. At the production site there must be:
a) job descriptions for all employees, specialists, engineers and managers;
b) instructions on specialties for employees of all professions of the enterprise;
c) instructions for the types of work performed.
17.2 Instruction on labor protection - a normative act that establishes the requirements for labor protection when performing work in industrial premises, on the territory of the enterprise, on construction sites and in other places where these works are performed or official duties are performed.
Labor protection instructions can be typical for employees of enterprises, sites and a particular workplace.
17.3. Instructions on labor protection can be developed both for workers of certain professions, and for certain types works.
17.4. Instructions for workers engaged in blasting, maintenance of electrical installations and devices, hoisting machines, boiler plants, pressure vessels, and for other workers whose labor safety requirements are established in intersectoral regulations on labor protection, approved by supervisory and controlling bodies of the Republic of Kazakhstan are developed on the basis of these acts and approved in the manner established by these bodies.
17.5. The requirements of normative acts on labor protection, included in the instructions, must be set out in relation to a specific workplace and the actual working conditions of the employee.
17.6. For new productions being put into operation, it is allowed to develop temporary instructions for employees. Temporary instructions should ensure the safe conduct of technological processes (works) and the safe operation of equipment. The same requirements apply to the development of temporary instructions as to the development of permanent instructions for employees. Temporary instructions are developed both by profession and by type of work for a period until the acceptance of these industries for operation by the state acceptance commission.
17.7. Instructions for employees are approved by the head of the enterprise after preliminary consultations with the labor protection service, and, if necessary, with other interested services and officials at the discretion of the labor protection service.
17.8. Each instruction must be given a name and a number. The title should briefly indicate for which profession or type of work it is intended.
17.9. Checking instructions for workers by profession or type of work for compliance with their requirements in force state standards, safety rules, sanitary norms and rules, hygiene standards should be carried out at least once every 5 years, and for professions and types of work associated with increased danger - at least once every 3 years. If necessary, proposals for their updating are developed.
Before the expiration of the specified periods, the instructions are revised when legislative acts, state standards and other normative documents on labor safety.
Development of Production Instructions! Full Schedule!
By order of higher authorities; when implementing new technology and technology; according to the results of the investigation of industrial injuries, accidents, disasters; when it changes standard instruction; when changing the technological process or working conditions, as well as when using new types of equipment, materials, apparatus, fixtures and tools.
Responsibility for the timely verification and revision of the instructions lies with the heads of the development departments.
If during the above period the working conditions of employees at the enterprise have not changed, then by order (instruction) for the enterprise, the operation of the instruction for employees is extended for the next period, which is recorded on the first page of the instruction (the “Revised” stamp is put, the date and signature of the person responsible for reviewing the instructions).
The heads of enterprises provide instructions to all employees and heads of interested departments (services) of the enterprise.
17.10. The issuance of instructions to the heads of departments (services) must be carried out by the labor protection service with registration in the journal for issuing instructions.
17.11. The head of the subdivision (service) of the enterprise must constantly keep a set of instructions in force in the subdivision (service) for employees of all professions and for all types of work of this subdivision (service), as well as a list of these instructions approved by the head of the enterprise.
17.12. Each site manager, foreman, etc. kit must be available current instructions for workers employed in this area, in all professions and types of work.
17.13 Instructions to employees can be handed out, against signature in the briefing log for study during the initial briefing, or posted at workplaces or areas, or stored in another place accessible to employees.
Publication date: 2015-10-09; Read: 2521 | Page copyright infringement
I consider my most valuable quality to be the ability to arouse enthusiasm in people and develop what is best in a person by recognizing his merits and encouraging him. (Charles Schwab, American manager)
ISO 9000 Work instructions
Askarov E.S. Associate Professor KazNTU named after. K. Satpaeva
Work instructions represent the third (lower) level of quality system documents. These instructions describe step by step how a specific simple operation production, assembly, installation of equipment, maintaining it in working condition, etc.
The work instructions also state how product quality can be controlled, what means can be used, what measuring equipment can be used, etc.
Organizational standards (company standards) are mainly used as work instructions. Here it should be noted that according to the law "On technical regulation", which came into force in Kazakhstan in 2005, the implementation of standards becomes voluntary, the state will exercise control over the safety of products for the health of consumers through technical regulations. Companies will be able to manage their own economic activity, guided by the interests of their business, for this it is necessary to be able to draw up their own regulatory documents, their own standards, the number of which will increase significantly. When drawing up standards, it is necessary to be guided by the requirements of the standard ST RK 1.5 - 2004. " General requirements to the construction, presentation, design and content of standards.
The main standards of organizations:
1. Production of project products
The organization shall establish, plan and maintain processes life cycle design products:
— marketing,
- analysis of contracts,
– development of a project for the production of design products,
— purchases related to the production of project products,
— production of design products,
- sales of products.
2. Production of engineering services (installation, design work)
3. Standards for regulating the implementation of auxiliary processes of the QMS
3.1. Resource management
It is used in the process of managing resources required in the main production. Resources are:
- people (staff)
— infrastructure (buildings, working space, communications),
- suppliers and partners,
natural resources, raw materials,
- equipment, tools, means of production, etc.
3.2. Process and Product Evaluation Metrics
It is used to evaluate products, their production processes and auxiliary processes in the QMS. Metrics are documents with information about the current state of an object and a forecast for the future.
Types of metrics:
A) marketing metrics,
B) Project metrics: c associated with the policy of the organization, financial metrics, labor and time metrics, metrics on product defects in the production process,
C) End product metrics: n design products, engineering services, software products,
D) Metrics of quality management processes: o general metrics of quality management processes, customer satisfaction metrics.
Indicators in metrics are evaluated on the basis of a point, absolute or relative system:
- absolute units (for example, hours, tenge, kW, etc.)
- relative units - for example, in percentages, etc.
The choice of tool for visualizing the characteristics of products and processes depends on the creativity of the organization, and best of all it should be computerized documents in EXCEL format.
The simplest metric is a summary of indicators according to some criteria that determine the effectiveness of work for a certain period - a year, a quarter, a month.
Example. The enterprise produces wallpaper, to determine the efficiency of work, a metric of product quality indicators is compiled, three types of products are taken - wallpaper "Sail", "Shugla" and "Arman". The data is taken for the year quarterly.
Table 1 shows sales data for the year (thousand tenge), table 2 shows data as a percentage. The figure shows a graph of annual indicators, it is clearly seen that the best dynamics for Shugla products, the sales level is constantly growing and occupies a large part of the annual balance.
4. Organizational standards detailing the implementation of life cycle processes
The organization has the right to independently determine the depth and detail of the description of the processes. If a more detailed description of any LC process is needed, a separate standard can be developed for this process.
Standards:
contract analysis,
Purchasing management,
Calculation of the reliability of designed objects,
Control technological processes etc.
5. Regulations on divisions and job descriptions
Regulations on subdivisions should have the following structure:
General provisions
- appointment of the unit
- what documents are guided by
- who approves the organizational structure
- who appoints employees
- Who do employees report to?
2. The main tasks of the unit
3. Functions of the unit
4. Structure of the unit and organization of work
5. Rights and general duties of employees
6. Responsibility of employees
7. Interaction with other divisions and external organizations.
Job descriptions have the following approximate structure:
General provisions
- who is appointed and dismissed from office
- who is appointed (level of education, experience, qualifications)
- who obeys
- who is in charge
- who replaces in the absence
- what should you know
- what documents to follow
2. Purpose of the position
3. Job responsibilities
4. Rights and powers
5. Performance and efficiency indicators.
Head of Information Support and Technical Policy Department.
General provisions
1.1. The head of the information support and technical policy department is directly subordinate to Technical Director open joint-stock company Kazzheldortechnika (hereinafter - the Company).
Guided in its activities by the current legislation of the Republic of Kazakhstan, the Charter of the Company, the Regulations on the Department of Information Support and Technical Policy, other local and acts of the Company and this job description.
A person with a higher technical education and work experience in the field related to the activities of the department for at least 3 years is appointed to the position of head of the department of information support and technical policy.
The head of the information support and technical policy department must know the provisions of the Charter of the enterprise, the Laws of the Republic of Kazakhstan "On technical regulation", "On ensuring the uniformity of measurements", "On labor protection", "On labor", other legislative acts of the Republic of Kazakhstan, the Provisional charter railways Republic of Kazakhstan, other guidelines in the field of railway transport and this job description.
Responsibilities
2.1 Development of quarterly and annual plans, generalization of measures for the comprehensive development of the Company and control over their implementation.
2.2. Ensuring the development and reconstruction of existing industries.
2.3. Supervising the timely installation and commissioning of new equipment.
2.4. Control over compliance with the Law of the Republic of Kazakhstan "On labor protection", Rules and instructions for labor protection and safety of railway workers.
2.5. Control over the introduction of new equipment, advanced technology, preparation of the economy for work in winter conditions.
2.6. Compliance with the regime of secrecy and the implementation of the necessary measures to protect classified official information from disclosure.
2.7. Methodological, legal and Information Support branches of the Company.
2.8. Ensuring and organizing work on the implementation of a system for automating container transportation and accounting for the container fleet by numbers.
2.9. Preparation of proposals for the adjustment of existing accounting and reporting forms.
Production instruction???
2.10. Bringing operating costs in line with the actual volume of work.
2.11. Development and control of uniform reporting forms for all indicators.
2.12. Participation in the development of draft agreements on issues related to the scope of the department, development of draft orders, orders and other acts of the Company.
2.13. Consideration of appeals government agencies, letters, statements from legal entities.
2.14. Organization of control over the state of labor and performance discipline by the employees of the Department.
2.15. Making suggestions for optimization organizational structure Society.
2.16. Ensures the implementation and implementation of the requirements of the quality management system in the department.
3.1. The head of the department has the right to give instructions to the branches of the Company on issues within the scope of the department.
3.2. Demand from the affiliated employees background information and reporting on issues within the scope of the department.
3.3. Sign internal documents with the consent of the Company's management.
4. Responsibility
4.1. The head of the department is responsible for:
- improper performance of their duties;
- the quality of work performed in accordance with job responsibilities;
— the correctness and completeness of the use of the submitted rights;
- Ensuring the fulfillment of planned targets assigned to him and his subordinates;
— non-observance of obligations in the field of quality and requirements of the quality system;
- low performance discipline;
- not following the rules internal regulations;
- fulfillment of the tasks provided for by this regulation, current legislation, orders, instructions;
— maintaining the confidentiality of information that is not subject to disclosure.
for damage caused to the Company in case of damage material assets in accordance with the Law of the Republic of Kazakhstan "On Labor in the Republic of Kazakhstan".
— is responsible for the quality of work in accordance with the Regulations on the department, job description, compliance with quality obligations and QMS requirements.
5. Order of appointment, release and replacement
5.1. The Head of the Department is appointed (released) to the position by order of the President of the Society.
5.2. In case of temporary absence (business trip, vacation, sickness), he is replaced by the chief specialist.
I read the instructions and received 1 copy.
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ISO 9000 Quality manual
How to describe and optimize business processes
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A production instruction is a provision that reflects the entire range of relations that develop between an employee of an organization and its products, as well as technical work that takes place in the enterprise. For a certain specialist, an individual official normative act is developed. All paragraphs of this provision take into account numerous aspects. With an increase in the magnitude of complex and dangerous factors production instructions reflect an increasing number of legal documents.
Official positions are universal and do not have a specific standard. The production instruction, due to the fact that it is based on in large numbers legislative acts, does not allow deviating in the processes. Documents that are used in the development official positions for various specialties, regulate the professional actions of employees. These functions are reflected in the form of production behavior, which, in turn, is formalized in the form of a production instruction. The main purpose of this document is:
Illumination of detailed instructions and rules for working with mechanical stationary systems that have start-up and installation of both manual and automatic nature;
Establishment of requirements regarding the magnitude of the workload for each specific profession;
Definition general level vibrations;
An indication of the magnitude of the thermal effect, which is calculated based on the seasons, as well as the duration of this effect, etc.
The production instruction reflects one of the essential factors of the production process - the severity of labor activity. It is determined on the basis of knowledge of the mass of goods that must be lifted and moved manually. To calculate gravity professional activity it is necessary to determine the dynamic load produced on the body of the worker during one shift. The unit of measure for this indicator is kilograms. severity labor process determined for those employees who are employed physical activity.
The production instruction prescribes the right of employees to comply with conditions that satisfy labor protection requirements. According to the Labor Code of the Russian Federation, employees are set state guarantees. At the same time, the employer has an obligation to ensure safe conditions and compliance with labor protection requirements. The Labor Code of the Russian Federation prescribes the need for control and state supervision for the implementation of all prescriptive actions. At the same time, this legislative act also establishes liability for violations of all requirements relating to these provisions are also reflected in the job descriptions of specialists.
Production regulations reflect the minimum standards that are intended to provide employees with overalls and footwear, as well as This provision is mandatory for safe working conditions and should not be violated by either the employer or the employee.
Can serve as hiring. At the same time, they can be approved as a separate document. Those who draw up job descriptions (usually these functions are assigned to the personnel department of the enterprise) have the right to seek advice from specialists. In your work, you can also use numerous regulatory documents. Yes, based on labor agreement and in full accordance with the Labor Code of the Russian Federation and other legislative acts that regulate legal relations in the field of labor, is drawn up job description foreman and worker, foreman and economist, director and chief accountant, etc.
This is an operational document of the organization, intended for servicingoperating personnel of the HIF, prescribing the procedure for performing job duties in the conduct of technologychemical process.
Contents A The definition of the production instruction is established by the Federal norms and rules in the field of industrial helmet security, guidance documents organizations, taking into account the specifics of production and operation at controlled technical devices.
Example with d Keeping the production instructions:
1. General Provisions;
2. Information about briefings and knowledge testing;
3. Subordination and relationship with related jobs;
4. Rights, obligations, responsibility;
5. Acceptance and delivery of the shift;
6. Description of the workplace, materials, equipment, technological scheme, norms of the technological mode;
7. Start and stop equipment;
8. Deviations from the normal technological mode and methods for their elimination;
9. Emergency stop;
10. Basic rules for safe work.
Appendix ie: Drawing of the technological scheme.
Instructions approved by the head or technical manager of the organization operating the HIF.
Changes are made to the production instructions or the document is completely revised in case of changes in regulatory documents, guidance documents organizations , which are the basis for the development of production instructions.
Order ra proi production instructions, you can contact us by phone +7 (495) 973-41-73 or by sending a request by e-mail This email address is being protected from spambots. You must have JavaScript enabled to view.
1. General safety requirements
1.1. Persons at least 18 years of age who have passed a medical examination, trained according to the relevant program, and who have passed introductory and workplace safety briefings are allowed to perform the duties of a locksmith for the repair and maintenance of hoisting machines.
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 by visual-measuring control metal structures, mechanisms, limiters, indicators, registrars and control systems of PS;
- 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 to perform the installation (dismantling) of the PS;
- 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, vocational training on 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;
- assortment and purpose lubricants used to lubricate mechanical equipment;
- ways to provide first aid to victims medical care, 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 operated 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 dangerous and harmful factors of production: 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 working 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 should have a slightly convex, not oblique and not knocked down, without cracks, the surface of the striker, should be securely fastened to the handle by wedging with pointed wedges, should 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 throat 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);
operation of the brake of the load lifting mechanism (checked by a load equal in mass or close to the rated load capacity of this machine when lifting it to a height of 200-300 mm; when stopping at the indicated 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 operation
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 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 conducting periodic inspections lifting machines, a thorough check of the condition of all mechanisms, cargo ropes, hook suspension, 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 neck;
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 hoisting machine, such as gears, shafts, ratchets, sprockets, keys, etc., were covered with fences of the 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. At the end of the repair or Maintenance it is necessary to make an appropriate entry 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. Put in order 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.
