基于层次模型的维修备件分类和设备管理研究

上海交通大学硕士学位论文基于层次模型的维修备件分类和设备管理研究姓名：钱春平申请学位级别：硕士专业：工业工程指导教师：奚立峰;谈俭军20090601I,(AHP),,,ABC,,B:ABCABSTRACTIITHECLASSIFICATIONOFSPAREPARTSANDEQUIPMENTMANAGEMENTSTUDYBASEDONHIERARCYMODELAbstractSparepartsplanningandmanagementisbecomingamajorproblemoftheplandepartmentandmaintenancedepartmentinthecompany.Theenterprisesoftenfacesthiskindofconfusion:ononehand,itisdifficulttoknowwhenthefailuresoftheequipmentswilloccurandthenwhatkindofsparepartsrequired.Butwheneverwemeetwiththisissue,sparepartsmustarriveonsiteasquickaspossible;ontheotherhand,althoughenterpriseshavereservedalargeamountofspareparts,theshortageofsparepartsalwayshappens.Butothersparepartsareoftendumpedatthecornersothattheywilloccupymuchinventoryandcapital.Basedonthecurrentbusinesssituation,thisresearchuseAnalyticalHierarchyProcess(AHP)astooltoclassifiyspareparts.Thecriticalclassificationofequipmentsisthefundamentalpartofthestockmanagement,whiletheequipmentengineerhasclearinformationabouttheclassificationofequipment.Thisresearchdiscussestheclassificationofequipments,whichmainlyincludeABCclassificationthroughexperiencedetermentandABCclassificationthroughdatastatistics,two-stagemethodclassificationofequipmentbasedonAnalytichierarchyprocess(AHP).Inthefinal,thecompanycandosometaskstoimprovethestockmanagementbasedoncorrectclassificationoftheequipments.Thisresearchwillprovideareferencetooltotheequipmentmanagers(BLogisticsCo.Ltd)andsupplyhelptosolvetheshortageofsparepartscausedbyunnecessarydowntimeloss.KEYWORDS:spareparts,stockmanagement,ABCclassification,two-stagemethod,analytichierarchyprocess,totalproductivemaitenance1()3.ABC[1]1.11.1.1,.:[1]1.1.21-,221.1.3[2]11Fig.1Thetargetofstockmanagement()(,CS),1.1.4,,,BOM,,,,,,,,,(Cs)320%80%,80%20%,()(,CS),,1.2;;[3][4][2][4]12060AllenPeter(1988)(top-down);Cohen1992):;Moore1996);R.Dekker1998);Braglia(2004)[3][4]ABC3A[6][5]ABC24Flint1995450Bayesian[2][3][8],,,[9]3Muckstadt1980)Hausman1994)SherbrookeMETRIC(Multi-EchelonTechniqueforRecoverableItemControl)(1968).METRICMOD-METRIC(1973)[2][3][4]4[11](1999)1.5250070001000(2/5)32090BridgmaMou-Campbell,1993)5Petrovic(1990)Sparta(SparePartsAdvisor)(1992)SPARTAII(CondensedDesign)Marcelo(2000)5SmartSofftware610%1.3AJITB,,,,,22Fig.2Theoriginalstockmanagementflowofspareparts()()6,(B),,,,B.B,,,33Fig.3Theactualstockmanagementflowofspareparts11*:1B()BB,,,(*),,,,,,,,71.4,,,,ABCABCABCB3304500ABC8ABCABCABCAABCABCCABC;ABC;ABCBC2.1ABCAABBCC4ABC94Fig.4DiagramofproductionlineSeitenteilLinieUB2.UB1QRK4AufbauUGSeitenteilSchottplattUB2QRK7UBIQRK5QRK8QRK8QRK5SeitenteilLinie2ABC104AABAA40AJITA2.2ABCABCABCABCABCABCABC22P123456ABC112Q12345C1234D1234S1232.2.1ABC2ABCC.4D.4D.4C.43AA20AABABC12B50CCC302.2.2ABC[14]ABC2.2.3ABCABCABCABCABC132.2.43ABCAAACCC27AAABAAABAAABACABCAACBABCAACBACCABCBABABCAAACCBCBCCACBBCACBBC,BCCCCBCBCCCC2.3AHPAHP2.3.1Satty()70AnalyticHierarchyProcessAHPABC142.3.2AHP2.3.3AHP5i.ii.iii.--iv.v.5Fig.5AHPLogicalDiagramABC152.3.41-9331913579246844Cs1P2P……nP1P11b12b……1nb2P21b22b……2nb…………………………nP1nb2nb……nnb:iib=1jib=1/ijbijb=ikb/jkb(i,j,k=1,2,….n)ijbijb,C.I.(ConsistencyIndex)C.I.maxλ–n/n-1(2.1)maxλC.I.C.I.nABC16C.I.nC.I.R.I.(RandomIndex),1-15100055n12345678RI000.580.901.121.241.321.41n9101112131415RI1.461.491.521.541.561.581.59n3C.I.R.I.C.R.(ConsistencyRatio)C.R.=C.I/R.I(2.2)C.R.0.10C.R.0.10C.R.0.102.4(AHP),AHPAnalyticHierarchyProcessABC39AHPAHP2.4.164996ABC176Fig.6Equipmenttypesofresearchobject2.4.277Fig.7layerstructuremodelA9BCABC182.4.3193912345678966778ABC198200764333114263701501156060115640130034506060402004060015001525207231585022002007725212331261290035035200745402002201070095251502004020601200500120400209080295020078320118146192032002022520240108560600201152080102290100010185101301061202007935032015036704230161455202708086102100110120207060150017005019520125255030200710ABC2084011220133328035760105330208803528008060804520180205001952545270203903518002008118144501501821972525107502340225275525153600600601598122373501210145242007620082992007.92008.2229104834240241333682T212551067562282382384445511877Tm85437734443681541203215193624(Tm/T)0.400.740.500.700.650.500.480.380.318910ABC210501001502002503003504008Fig.8statisticsdiagramofbreak-downtimes010002000300040005000600070009Fig.9statisticsdiagramofbreak-downtotaltimeABC2201000200030004000500010Fig.10statisticsDiagramofproductionhalttime1010TmTTm/T10111112ABC23121313141415151616ABC2417172.4.419191-91-91ka−1-91ka−k↔1ka−k=1,2,3,,9(2.3)k19191919195nen=0,1,281111Fig.11JudgementMatrixofcriterionlayerABC25,1212Fig.12JudgementMatrixofQualityitem1313Fig.13JudgementMatrixofsysteminfluence,1414Fig.14JudgementMatrixofdefectfrequency,1515Fig.15JudgementMatrixofsafetyitemABC261616Fig.16JudgementMatrixofdown-timeloss,1717Fig.17JudgementMatrixofmaximumworkingability1818Fig.18JudgementMatrixofmaintenancedifficulty1919Fig.19JudgementMatrixofworkingcostABC272020Fig.20JudgementMatrixofmonitoringdifficulty2.4.5e^(0/5)~e^(8/5),1819181.0.0080;1.0000Wi1.00001.22141.00001.49181.22144.95301.82214.05522.22550.18450.81871.00000.81871.22141.00002.71831.22141.49181.22