基于rcm的显示器装配线设备故障停线率改善

上海交通大学硕士学位论文基于RCM的显示器装配线设备故障停线率改善姓名：苗惠贞申请学位级别：硕士专业：工业工程指导教师：周炳海;田树起20071101IIIRCMAAAIVA:VDisplayAssemblyLineEquipmentShutdownLossImprovementBasedonRCMABSTRACTAlongwiththefastdevelopmentofdisplaymanufacturingindustry,companyAdecidestocontrolitscostofqualitysoastofulfillmenttheproductivitypromotionstrategy.Thelineequipmentshutdownlossshouldbecontrolledwhenitisintroducedintotheinternalfailurecostofquality.Toimprovetheequipmentrunningreliabilityandreducethefailurerateoftheequipment,thedisplayassemblylineistakenastheresearchobject.Thisthesisdiscussesthetheoryapplicationofreliabilitycenteredmaintenance(RCM)inthedisplayassemblylineequipmentmanagement.UsingRCM,thetopicdefinesfivecriticalequipmentbasesonthecategoryandanalysisofthehistoricaldataofequipmentrunningandmaintenancerecordin2005;setsupequipmentreliabilityperformanceindicatorwithtwoshiftsproductionbasesonthereliabilityparameteranalysis;settlescriticalequipmentmaintenanceitemandestablishesequipmentmaintenancesequencebylogicwayafterfaulttreeanalysissoastoprovidetheguidelinestotheequipmentdailycheckingschedule;determinestheoptimalpreventivemaintenancecycleforcriticalequipmentbasesonVIpotentialaccidenttheory;validatestherationalityofRCMapplicationresultondisplayassemblylineequipmentmanagementfromthestatisticrealdataappraisalsofequipmentreliabilityperformanceindicatorandthefailurerateofequipment.Asaresult,theexecutionofRCMhelpscompanyAtomeetthetargetofequipmentshutdownlossreduction,benefitstocontrollingcostofqualityandfulfillingenterprisestrategy.ThepracticeofRCMondisplayassemblylineequipmentmanagementshouldbedevelopedfurthermore.KEYWORDS:ReliabilityCenteredMaintenance;CriticalEquipment;PreventiveMaintenanceAssemblyLineIII11.11.1.1A,,AAA(OrganizationandEfficiency)1.1.2A.V.[1]1956PAFPrevention-Appraisal-FailureApproach,211Tab.1QualityCostAnalysisA1.1.33A1.2121Fig.1DescriptionofTotalMaintenanceCost42Tab.2CostLossofMaintenanceFailure1950195019751975RCMBCMTPMLCC(ReliabilityCenteredMaintenance,RCM),[2](BusinessCenteredMaintenance,BCM)[3]BCM[4](TotalProductiveMaintenance,TPM)5[5][6](LifeCycleCost,LCC)[7]33Tab.3MaintenanceManagementOpinionAppraisalRCMBCMTPMLCC61.3A20050.38%/100%342KRMBA0.38%0.15%1.4ARCM[8][9]1.57RCMRCMMTBFMTTRRCMRCM8RCMRCM(ReliabilityCenteredMaintenance),RCMRCMRCM2.1RCM2.1.1RCM7080RCM(Reliability-CenteredMaintenance)6074770RCM9RCMRCM2.1.2RCMRCMRCMRCM[10]1.2.3.4.5.6.7.RCM101.RCMRCM2.RCM3.4.5.6.RCM117.RCM7RCM[11][12]2.1.3RCMRCM[2]RCM1.2.RCM3.4.RCM1.2.RCM123.4.2.1.4RCMRCM1.2.3.4.RCM132.2RCMRCMRCM1.2.3.4.5.6.7.8.9.2.3RCM[13][13]RCM14[14]AARCMRCMRCMRCM153.12Fig.2DisplayAssemblyLineScopeA21636+/-53Fig.3DisplayAssemblyLineFlowChart33.2RCMRCM4MTBFMTTR174RCMFig.4RCMAnalysisFlowChart3.3....MTBFMTTR....MTBFMTTR.183.3.12005A20050.38%0.34%,91.4%0.027%,7.2%5:195Fig.5EquipmentShutdownLossBreakdown3.3.2AABC0.38%7.2%91.4%1.4%20ABCABCABCA20%80%ABC20%20%80%20%6ACriticalEquipment6A2005.)Hrs(.)Hrs(=161200571.3515.5,13.411.58.57.5121==%72.2135.715.15=21.72%,(18.78%)(16.12%)(11.91%)(10.51%)79.05%ABC1202171.35:0.38%Year:2005PLCA/MsignalWrappingTurnOverYTD.HRS15.5013.4011.508.507.502.001.701.651.501.401.251.201.101.000.800.500.400.250.2071.35%21.72%18.78%16.12%11.91%10.51%2.80%2.38%2.31%2.10%1.96%1.75%1.68%1.54%1.40%1.12%0.70%0.56%0.35%0.28%100%Par.21.72%40.50%56.62%68.54%79.05%81.85%84.23%86.55%88.65%90.61%92.36%94.04%95.59%96.99%98.11%98.81%99.37%99.72%100%Loss19981775135813949134933875093424044333883843233862031695510712021Frequency142817256865445575453111533209399A024681012141618PLCA/MsignalWrappingTurnOver0%20%40%60%80%100%120%YTD.HRSPar.79.05%6Fig.6EquipmentShutdownLossPareto71122121.72%,77Fig.7AutoStrappingMachine218.7%,88Fig.8AgingLiftMachine23316.1%,9411.9%,109Fig.9ChainConveyerSystem10Fig.10PackingDevice24510.5%,1111Fig.11BeltMachine3.43.4.1(part)(component)(product)25(system)(integrity)[15][16]3.4.2RCMRCM71.()2.3.4.5.6.7.RCM7RCM,126T0.35TT//PLC122712Fig.12AutoStrappingMachineFunctionBreakdownChart2PLCPLC28/1313Fig.13AgingLiftMachineFunctionBreakdownChart3//291414Fig.14ChainConveyerSystemFunctionBreakdownChart4/301515Fig.15PackingDeviceFunctionBreakdownChart5311616Fig.16BeltMachineFunctionBreakdownChartRCMRCM324.14.1.1a.b.c.d.[17][18]1MTBFMTBF(MeanTimeBetweenFailure)N,t,......,t,tN21NTtN1MTBFN1ii==∑=2T2MTTRMTTRMeanTimeToRepairRestoration33MTTR∑==N1iintMTTR3it---in---3AitτAt,τiA,MTTRMTBFMTBF+=iA4iA-iMTBF-iMTTR-i4iA34MTTRMTBFMTTR+=iA(5)iA-iMTBF-iMTTR-i[19]100%4.1.2AAA25/8AMTBFMTTRAiiA220052005A35522005149301998A162540024000MTBF(h)MTTR(min)a.MTBF2342.9h1440012MTBF=×==b.MTTR3min6614930MTTR===c.Ai4%680.99%10066609.342609.342MTTRMTBFMTBF=×+××=+=iAd.iA5%320.0%10066609.34266MTTRMTBFMTTR=×+×=+=iA4ATab.4CriticalEquipmentReliabilityTarget—BeforeImprovementppmMTBFhMTTR(miniA%iA%753342.96699.6800.320652171.42999.7190.281560282.44199.7590.2414131922099.8270.1733658007599.8440.15636MTBFMTTRAiiA44.2RCM—RCM[20]RCM[21][22]4.2.1[23][24](FaultTreeAnalysis)FTAFTA1961H.A.WatsonD.F.Hansl19651974Wash-1400FTA374.2.21FTAFTA2FTAFTAFTAFTA4.2.3FTA38FMEAn4.2.45[25]395Tab.5ClassicFaultTreeGatesandt