Fermentation Heating Tube Anti-Corrosion System Overall Operation & Performance Appraisal Comprehensive Management Specification

# Fermentation Heating Tube Anti-Corrosion System Comprehensive Management Specification (Doc.80) ## Preface Documents No. 33–79 comprise a comprehensive closed-loop anti-corrosion standard system that encompasses the following: corrosion mechanism, full-lifecycle equipment management, accident disposal, on-site SOP, risk early warning, supervision audit, document archiving, personnel training, document compilation, and release control. Doc.80 unifies a comprehensive performance appraisal system by incorporating hardware operation, process execution, maintenance implementation, personnel competency, document management, audit rectification, and economic loss control. It serves as the top-level management document for the full anti-corrosion system, integrating the organisational responsibility division, full-dimension appraisal index system, monthly/quarterly scoring rules, reward and punishment implementation mechanism, and continuous optimisation closed-loop logic. This eliminates scattered single KPI assessment, disjointed reward and punishment, unquantified overall operation effect, and unclear departmental accountability. # Chapter 1: Comprehensive Organisational Responsibility Division of Anti-Corrosion System Operation ## 1.1 Core Management Hierarchy & Boundary of Duties 1. Factory Equipment Management Department (Overall Leading Department) - Develop annual anti-corrosion objectives and assign monthly/quarterly targets to each workshop; - Conduct quarterly cross-departmental factory-level audits, supervise Doc.79 document release and version control, and coordinate major hardware transformation investments; - Conduct comprehensive quarterly performance evaluations of each workshop and establish factory-level reward and accountability. 2. Workshop Production & Equipment Joint Management Group (On-Site Execution Main Body) - Organise tiered training and competency certification in accordance with Doc.75; complete hardware transformation, routine maintenance, and hidden danger rectification on schedule; - Decompose workshop anti-corrosion targets to each production shift and maintenance team; - Execute daily spot checks, weekly special audits, and monthly comprehensive internal audits in accordance with Doc.70; - Count monthly anti-corrosion KPI data and submit performance scoring materials to the factory equipment department by the 5th of each month. 3. Production Frontline Shifts (Process Execution Unit) - Must strictly adhere to the fermentation and CIP anti-corrosion SOP (Doc.59); complete daily patrol records, abnormal timely reporting, filter cleaning, and static standby control; accept daily supervision spot checks, participate in monthly training and assessment, and bear direct responsibility for human-induced forbidden misoperations. 4. The Equipment Maintenance Team (Hardware & Maintenance Execution Unit) is responsible for the following tasks: completion of pipeline dead zone reconstruction, filtration/interlock hardware upgrading as scheduled, implementation of standardised disassembly and assembly, periodic maintenance, and consumable replacement per cycle, completion of monthly quantitative testing, quarterly comprehensive overhaul, post-overhaul double CIP flushing, and tracking of heating tube full-lifecycle archives (Doc.71). 5. Quality & Safety Department (Supervision & Auxiliary Audit Unit) - Conduct a quarterly cross-audit of the factory to ensure that the anti-corrosion operation complies with production quality control requirements; - Audit the major red risk emergency disposal procedures and accident batch loss risk control. ## 1.2 Annual Overall Anti-Corrosion Core Targets (Decomposed Monthly/Quarterly) 1. Equipment Safety Objective: Achieve a zero-percent rate of sudden heating tube leakage/rupture accidents and a zero-percent rate of batch scrapping due to corrosion contamination. 2. Equipment Service Life Target: The average service life of all heating tubes meets or exceeds the baseline standard outlined in Doc.60. 3. Standard Execution Target: A monthly Class A major non-conformity count of 0; all core anti-corrosion KPIs must be ≥99.5%. 4. Personnel Competency Objective: A monthly training attendance rate of 100%; a staff assessment pass rate of ≥99%; and all operators possess valid qualification certificates (Doc.75). 5. Hardware & Document Target: The hardware transformation was completed with a 100% success rate. All on-site documents are the most recent, valid versions, and no expired or invalid documents were utilised. 6. Cost Control Objective: A continuous downward trend in the monthly cost of heating tube maintenance and replacement per cubic metre of fermentation liquid with respect to preceding years. # Chapter 2 Six-Dimensional Comprehensive Appraisal Index System (Matched with Full Set of Serial Documents) ## Dimension 1: Hardware Configuration & Equipment Operating Status (Weight 20%, Responsible: Maintenance Team): 1. Compliance rate for pipeline transformation (Doc.50, Doc.62): Dead leg, large-radius elbow, and auxiliary circulation transformation full compliance target ≥98% 2. Two-stage filtration and interlock equipment intact rate: pH/DO/temp/chloride interlock effective rate ≥99%, differential pressure alarm. 4. Material matching conformance rate: 100% compliance, no mismatched heating tube-medium pipeline layout. Gasket classified storage, on-time replacement, zero reused disassembled gaskets ≥99% consumable standardised management compliance rate. Monthly quantitative testing completion rate for heating tubes: 100% full bundle testing on schedule. ## Dimension 2: Production & CIP Process Standard Execution (Weight 30%, Responsible: Production Shifts, Highest Weight Core Module) 1. ≥99.5% compliance rate with medium environment parameters (pH/chloride/DO) 2. CIP full-process execution compliance rate (qualified rinsing endpoints, no skipped rinsing segments): 100% 3. Pass rate for CIP temperature and flow velocity control: ≥99.5% is four. Static standby safe time and mandatory delayed cooling implementation rate: ≥99% 5. The compliance rate of daily start-stop frequency within the material limit is at least 99%. Dimension 3: Patrol Inspection, Hidden Danger Rectification & Audit Closed-Loop (Weight 18%, Responsible: Shift Foremen + Equipment Supervisors): Target value 0 (each occurrence deducts hefty points) 1. Completeness of daily patrol records and timely abnormal reporting rate: 100% 2. Three-level risk hidden peril closed-loop rectification completion rate: 100% on schedule. The acceptance pass rate for non-conformity rectification in audits conducted on a daily, weekly, or monthly basis is at least 99%. The on-time completion rate of monthly/quarterly revision tasks is 100%. Zero recurrence rate of the same type of non-conformity after rectification: Target 100% ## Dimension 4: Personnel Training, Assessment & Competency Qualification (Weight 12%, Responsible: Production & Equipment Management) 1. The mandatory training attendance rate is 100% for pre-job, monthly, and quarterly emergency training. The pass rate for the theory and practical assessment, as per Doc.75, is at least 99%. The possession rate of valid post-qualification certificates among all on-site personnel is 100%. ## Dimension 5: Standard Document Compilation, Release & Archive Traceability (Weight 8%, Responsible: Equipment Document Administrator, Doc.71, Doc.79): 100% ## Supplementary training completion rate triggered by accidents/audit non-conformities: 1. On-site document valid version compliance rate: 100% compliance, zero self-altered documents, and no mixed old and new versions. Ledger completeness for document distribution, revision, and invalid destruction at 100%: 3. The completion rate of daily/monthly execution, testing, and accident archive dual backups is 100%. Completeness of full-chain data traceability during audit and accident investigations: 100% ## Dimension 6: Equipment Failure, Economic Loss, and Cost Control (Weight 12%, Core Result Assessment Module) 1. Monthly frequency of sudden heating tube failure: 0 times (major point deduction for each accident) 2. The target for the batch loss rate due to heating tube corrosion failure is 0%. Target: ≥100% of baseline 4 for the actual average heating tube service life completion ratio. Chapter 3 Standardised Monthly Scoring & Quarterly Comprehensive Grading Rules ## 3.1 Monthly Workshop Quantitative Scoring Calculation Logic Total full score = 100 points, weighted summation of six dimension scores; Monthly grade division standard: 1. Monthly maintenance & replacement cost per cubic metre of fermentation liquid: Year-on-year reduction as scoring standard. Grade A Excellent: A total score of 95 points or higher (qualifies for the full anti-corrosion collective reward) 2. Grade B Qualified: 85 points or less (basic performance remains unaltered; rectify any deficiencies within the month) 3. Grade C Unqualified: Total score - 85 points (submit a 7-day rectification improvement plan, deduct workshop overall equipment performance) ## 3.2 Monthly Shift & Maintenance Team Independent Scoring Rules ### Production Shift Monthly Scoring (Full Score 100) 1. Parameter compliance, CIP standard implementation, static/slow cooling control, and forbidden misoperation deduction (each forbidden misoperation deducts 10 points per time) (2) are process execution indicators (60 points). Patrol & aberrant reporting (20 points): Points are deducted item by item for incomplete records and delayed abnormal reporting by item 3. Staff training and evaluation (10 points): Four points are deducted for failed assessments and absences from training. Maintenance Team Monthly Scoring (Full Score 100) 1. Hidden danger rectification cooperation (10 points): Uncoordinated rectification deducts full item points. Hardware transformation and filtration/interlock intactness (35 points) 2. Periodic maintenance, testing, and consumable management (30 points) 3. Execution of audit non-conformity rectification and hidden peril (20 points) 4. Maintenance personnel training and qualification certification (15 points) ## 3.3 Quarterly Factory Comprehensive Grading & Annual Target Evaluation 1. Factory cross-audit score × 20% + average of three monthly scores × 80% = quarterly comprehensive score. Overall annual evaluation: The average of four quarterly scores, which are associated with the workshop's annual equipment management excellence evaluation qualification 3. Special deduction items (directly deducted from the quarterly total score, irreducible): - Occurrence of Class A major red risk accident resulting in heating tube leakage and batch loss: Deduct 15 points at a time. - Repeated recurrence of the same non-conformity after two rectifications: Deduct 8 points per item. - Mass loss of archives, long-term use of invalid outdated documents found in factory audit: Deduct 10 points. - Multiple staff without valid qualification certificates on post: Deduct 5 points per person. Chapter 4 Multi-Level Reward & Accountability Punishment Closed-Loop Mechanism ## 4.1 Reward Hierarchy Standard ### 4.1.1 Monthly Workshop Collective Reward (Grade A Excellent Only) 1. The anti-corrosion special performance incentive pool will be distributed to the workshop in a proportional manner to the production shifts and maintenance teams, based on the internal shift monthly scores2. Post a Grade A bulletin on the factory equipment management publicity board as a priority evaluation condition for the annual excellent equipment management workshop ### 4.1.2 Shift/Team Individual & Collective Incentives 1. Extra shift collective bonus and public recognition on workshop bulletin board 2 for zero forbidden misoperation shifts with a complete score of ≥95. The maintenance team has successfully completed all hardware transformation and maintenance duties without any hardware non-conformities. There will be a monthly team allowance of three. Individual incentives: - Staff who actively identify significant red hidden hazards and prevent equipment failure loss: One-time cash reward, recorded in personal performance file. - Staff who achieve full marks in monthly training assessments and maintain a valid certificate for a consecutive six months: Monthly individual competency subsidy. - Staff who propose optimised anti-corrosion operation/hardware transformation suggestions with verified effect: Special innovation reward ### 4.1.3 Annual Excellent Incentives Workshops obtaining four consecutive quarterly Grade A comprehensive evaluation: Extra annual anti-corrosion management one-time reward, priority for equipment transformation budget allocation in the following year. Level 1 Light Penalty (Class C minor non-conformity, blue hidden danger repeated omission) ### 4.2 Graded Accountability & Punishment Standard ### 1. Supplementary training during off-hours, individual verbal warning, no performance deduction, record in personal training file 2. ### Level 2 General Penalty (Class B non-conformity, yellow risk overdue rectification, repeated forbidden misoperations) 1. Shift written self-criticism, rectify all hidden dangers within 24 hours. Mandatory make-up assessment following retraining, individual monthly performance deduction. Level 3 Serious Accountability (Class A major non-conformity, red risk hidden danger, accident causing economic loss) 1. Corresponding shift/maintenance team partial deduction of collective bonus, submit written rectification plan to equipment supervisor. Written warning archived in personal file 2, joint performance double deduction for direct operator, shift foreman, and maintenance person. The workshop has been downgraded to Grade C unqualified, and the full anti-corrosion collective incentive for the third month will be withheld. Level 4 Special Administrative Accountability 1: Implement factory-level multi-level accountability, deduct workshop management performance, organise full-workshop re-training, and conduct unified assessment in response to a significant accident that resulted in batch loss. In the event of a mass loss of archives and the long-term storage of invalid documents, the document administrator should issue a warning notice and momentarily adjust the auxiliary management post until the rectification process is complete. Chapter 5 Continuous Optimisation Closed-Loop Operation Mechanism ## 5.1 Monthly Anti-Corrosion Operation Analysis Meeting (Mandatory Held Before the 10th of Each Month) Participants: Workshop director, equipment supervisor, all shift foremen, maintenance team leader, document administrator Core agenda: 1. Management personnel fail to organise training/audit as scheduled, resulting in an overall low qualification pass rate. Deduct management KPI score and submit a special optimisation improvement report. Sort out low-scoring weak links and announce the monthly scoring results for each shift/team; 2. Analyse the root causes of repeated non-conformities and compile monthly non-conformity classification statistics; 3. Summarise the situation of the month, which includes the rectification of a hidden peril, the failure of a heating tube, and the training assessment. Develop targeted optimisation strategies for the upcoming month, and alter the focus of supervision and training. Document the content of the meeting in the monthly anti-corrosion analysis report, which is archived in accordance with Doc.71. ## 5.2 Quarterly Factory Anti-Corrosion System Optimisation Review Meeting Participants: All workshop equipment management supervisors, factory equipment department, and quality department. Core agenda: 1. Comparing the annual target completion progress with the quarterly exhaustive grading results of each workshop; 2. Provide a concise summary of the typical corrosion failure cases that occur throughout the factory, and promptly revise the Doc.64 risk manual and Doc.59 SOP in the event that new risk modes arise. Assess the impact of the 12-month long-term optimisation plan in Doc.62 on its implementation and make necessary adjustments to the hardware transformation progress arrangement. Modify the weight, reward, and punishment standards of KPI scoring in accordance with the actual operations on site; 5. Publish a quarterly optimisation deployment document and monitor the impact of implementation during the subsequent quarter's audit. ## 5.3 Annual Overall System Evaluation & Target Adjustment At the conclusion of each year, the factory equipment department compiles full-year anti-corrosion data, which includes the heating tube service life, failure frequency, maintenance cost, KPI compliance rate, and training pass rate. The department also assesses the overall operation effect of the anti-corrosion system, adjusts the annual core targets for the following year, synchronously optimises the entire set of document parameter thresholds and appraisal scoring standards, and completes major version revisions of relevant documents in accordance with the Doc.79 approval process, if required. # Supplementary Provisions of Chapter 6 1. The top-level overall operation and performance appraisal management specification of the full fermentation heating tube anti-corrosion system is Doc.80. It is intended to be used in conjunction with serial documents No.33–79. This document shall govern all appraisal standards, reward and punishment execution, and organisational responsibility division. 2. The monthly scoring statistics, quarterly comprehensive grading, and annual overall evaluation organization are the responsibility of the factory equipment management department. Each workshop is responsible for the daily on-site decomposition execution and data truthful submission. 3. Dual electronic-paper backup archiving, as outlined in Doc.71, shall be implemented for all monthly scoring sheets, quarterly audit scoring reports, reward and punishment vouchers, and anti-corrosion operation meeting minutes. The retention period for factory audit and accident traceability must be at least three years. 4. This specification shall initiate a major version revision following four-level joint approval in accordance with the document compilation and release procedures outlined in Doc.79, and organise full-staff supplementary training in accordance with Doc.75, if the factory modifies the overall equipment performance appraisal system. ## Summary Doc.80 establishes a closed-loop, top-down operating and performance appraisal management system for the fermentation heating tube anti-corrosion system, which is fully covered by the staff. It establishes six-dimensional quantifiable appraisal indicators that encompass hardware, process, inspection, personnel, documents, and economic loss, as well as standardises monthly grading, quarterly comprehensive evaluation, and multi-level reward and accountability mechanisms. Additionally, it clarifies the division of responsibilities among factory functional departments, workshop management, production shifts, and maintenance teams. The issues of disjointed system execution, unquantified overall effect, and ambiguous responsibility accountability are resolved by the continuous optimisation mechanism, which is implemented in conjunction with the monthly analysis, quarterly review, and annual evaluation. It establishes a permanent driving force for the stable long-term operation of the heating tube anti-corrosion closed-loop management system, fundamentally reduces the frequency of corrosion failures, and fundamentally links all anti-corrosion standard implementation effects with tangible performance rewards and penalties. This drives all posts to strictly implement the full set of anti-corrosion documents from No.33 to 79.