制造业设备维修方式选择及维修模型研究

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摘要

设备是制造业的重要组成部分。设备维修管理对企业的生存与发展具有极其重

要的意义，随着企业设备规模的日益扩大和维修费用的逐年增长，世界各国对设

备维修管理提出了新的要求。作为延长设备寿命、降低生产成本和提高产能的有

效途径之一，设备维修备受关注。其一，不合理的维护所造成的维修不足或维修

过剩给企业带来的经济损失不可小觑。其二，设备的日趋复杂化为维修策略的制

定引入了越来越多的复杂因素，增加了其难度。正因如此，才凸显了对此类设备

预防性维修策略的制定方法进行研究的必要性。

本文正是针对上述问题，在简要阐述了设备维修管理的研究现状之后，提出

利用模糊综合评价法和 FMEA 法分别从设备重要度和设备故障模式为出发点，详

细介绍设备维修方式选择的方法。再以多目标决策法为依据，引入“七步走”框

架原理，对维修方式的选择、实施和优化问题进行了比较全面的研究。以制造系

统的瓶颈设备为主要研究对象，以设备可用度最大化为决策原则进行维修策略的

优化研究。在深入剖析维修周期及其与设备可用度关系的基础上，运用时间延迟

理论对设备的预防性维修策略问题作了探索性的研究，建立预防维修优化模型，

并用 K-S检验方法对优化的预防性维修模型的拟合度做了检验。理论研究的同时，

结合实例验证理论的有效性，并且对当前维护计划和本文提出的改进时间延迟模

型的优化结果三种情况进行了全面的分析比较。结果表明本文所提出的方案能更

有效地降低设备的非计划停机时间，从而达到更有效的提高设备效率的目的。

研究表明，对现行管理结构中不利于设备维修管理部分进行局部调整，学习

国际先进的设备维修管理理念，大力应用推广新设备、新技术，应用新的管理办

法，就能有效地改善管理维修管理水平，增强企业的竞争能力。

关键词：设备维修方式 “七步走”框架原理模糊综合评价法 FMEA

预防维修时间延迟

制造业设备维修方式选择及维修模型研究

ABSTRACT

Equipment is the most important portion of the manufacturing industry. The

equipment maintaining management has much meaning to the survival and

development of the corporation．New requirements have been put forward on equipment

maintenance management in various countries, because of increasing cost with

increasing size of equipment．As a method of prolonging the lifecycle of equipment,

cutting down the cost of production and boost productivity, equipment maintenance is

attracting much attention. On one hand, insufficient or too much maintenance caused by

unreasonable maintenance will cause huge loss to enterprises. On the other hand, the

increasing complication of modern equipments brings more and more complex factors

to its maintenance planning. However, these challenges call for the necessity of

studying maintenance strategy formulation in such industry.

This paper is designed for above-mentioned problems. After a brief introduce on

the status of equipment maintenance, the author chooses the maintenance mode

respectively by using the fuzzy comprehensive evaluation and FMEA on the basis of

analyzing the importance and fault of equipments. Then it introduces the 7-step

framework on the basis of multi-objective decision-making method. Centered on

bottleneck equipments in manufacturing industry and following equipment availability

maximization principle, this thesis is devoted to optimizing the maintenance strategy.

On the basis of the analysis of equipment maintenance cycle and its relationship with

equipment availability, an improved application method of the delay-time-based

maintenance model is proposed to optimize the overall maintenance scheduling. The

optimized model is examined by K-S test. Combined with the theoretical research, the

thesis examples the validity of the theory. The comparison analysis of different

solutions given by different application approaches shows the improved method

proposed in this thesis can reduce unscheduled downtime and enhance equipment

efficiency more significantly.

The research indicates that we can converse the traditional concept, and rectify the

loss of the equipment management in present administration framework; we should

learn from the international advanced equipment maintaining management concept, to

apply extending new equipment and new technology; we can effectually improve the

level of the maintaining management and build up the competition of the corporation.

第一章绪论

III

Key words: Equipment maintenance strategy, 7-step framework,

Fuzzy Comprehensive Evaluation，FMEA, Preventive maintenance,

Delay time, Availability

制造业设备维修方式选择及维修模型研究

中文摘要

ABSTRACT

第一章绪论 .................................................................................................................... 1

1.1 研究背景及意义 ................................................................................................ 1

1.1.1 背景 ....................................................................................................................... 1

1.1.2 研究意义 .............................................................................................................. 2

1.2 国内外研究现状与评价 .................................................................................... 3

1.3 研究内容 ............................................................................................................. 5

1.4 研究思路 ............................................................................................................ 6

第二章设备维修管理综合评述 .................................................................................... 8

2.1 设备 .................................................................................................................... 8

2. 2 设备管理 ........................................................................................................... 9

2. 3 设备维修 ......................................................................................................... 10

2.3.1 设备维修工作 .................................................................................................... 10

2.3.2 设备维修方式 .................................................................................................... 10

2.3.3 设备维修方式选择的影响因素 ..................................................................... 12

2.3.4 设备重要度评价指标体系 .............................................................................. 13

2.4 本章小结 .......................................................................................................... 14

第三章设备维修方式选择与优化 .............................................................................. 15

3.1 设备维修方式选择的现状 .............................................................................. 15

3.2 维修方式适用性分析 ...................................................................................... 16

3.3 基于模糊综合评价法的设备维修方式选择方法 .......................................... 17

3.3.1 基本思想 ............................................................................................................ 17

3.3.2 具体应用过程 .................................................................................................... 18

3.4 基于 FMEA 的设备维修方式选择方法 ......................................................... 19

3.4.1 FMEA 及其应用 ................................................................................................ 19

3.4.2 理论方法的基本原理 ....................................................................................... 20

3.4.3 故障发生频率(Occurrence) ............................................................................. 20

3.4.4 严重性(Severity) ............................................................................................... 20

3.4.5 可检测性(Detectability) ................................................................................... 21

3.4.6 危险优先数(Risk Priority Number，RPN) ................................................... 21

第一章绪论

3.4.7 具体应用过程 .................................................................................................... 22

3.5 “七步走”设备维修方式的选择模型 .......................................................... 22

3.5.1 “七步走”框架原理的基本思想 ................................................................. 23

3.5.2 “七步走”框架原理的具体方法 ................................................................. 23

3.6 本章小结 .......................................................................................................... 28

第四章基于时间延迟的维修周期优化模型 .............................................................. 29

4.1 基于可用度最大化原则的预防维修模型 ...................................................... 29

4.1.1 预防维修 ............................................................................................................ 29

4.1.2 可用度 ................................................................................................................. 30

4.2 时间延迟概念及其维修理论 .......................................................................... 30

4.3 优化模型的建立 .............................................................................................. 32

4.3.1 相关符号 ............................................................................................................ 32

4.3.2 模型的假设条件 ............................................................................................... 33

4.3.3 模型的建立 ........................................................................................................ 33

4.4 模型的求解 ....................................................................................................... 34

4.4.1 时间延迟概率密度函数参数估计 ................................................................. 35

4.4.2 模型拟合度检验 ............................................................................................... 35

4.5 本章小结 .......................................................................................................... 36

第五章案例分析 .......................................................................................................... 37

5.1 某烟草制造企业设备维修方式选择 .............................................................. 37

5.1.1 企业简介 .............................................................................................................. 37

5.1.2 企业的设备维修决策现状 .............................................................................. 37

5.2 基于模糊综合评价法的设备维修方式选择 .................................................. 39

5.3 基于 FMEA 的设备维修方式选择 ................................................................. 41

5.4 基于“七步走”框架原理的设备维修方式选择 .......................................... 41

5.5 预防维修优化模型维修周期的确定 ............................................................... 44

5.5.1 缺陷发生率的确定 ........................................................................................... 44

5.5.2 时间延迟概率密度函数的确定 ..................................................................... 45

5.6 本章小结 .......................................................................................................... 48

第六章总结与展望 ...................................................................................................... 49

6.1 总结 .................................................................................................................. 49

6.2 展望 ................................................................................................................... 50

制造业设备维修方式选择及维修模型研究

参考文献 ........................................................................................................................ 51

攻硕期间主要的研究成果 ............................................................................................ 55

致谢 ................................................................................................................................ 56

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摘要：

I摘要设备是制造业的重要组成部分。设备维修管理对企业的生存与发展具有极其重要的意义，随着企业设备规模的日益扩大和维修费用的逐年增长，世界各国对设备维修管理提出了新的要求。作为延长设备寿命、降低生产成本和提高产能的有效途径之一，设备维修备受关注。其一，不合理的维护所造成的维修不足或维修过剩给企业带来的经济损失不可小觑。其二，设备的日趋复杂化为维修策略的制定引入了越来越多的复杂因素，增加了其难度。正因如此，才凸显了对此类设备预防性维修策略的制定方法进行研究的必要性。本文正是针对上述问题，在简要阐述了设备维修管理的研究现状之后，提出利用模糊综合评价法和FMEA法分别从设备重要度和设备故障模式为出发点...

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