自动生产线的同步维修模型及实例研究

Group Maintenance Model of Automatic Production Line and Its Application

自动生产线故障停机时间长、停机费用高,其原因在于:设备种类多且相关联,存在各设备协同维修的难题。首先,寻求生产线故障时间和检查时间之间的平衡点,建立检查周期与总停机时间之间关系的目标函数。其次,借鉴同步维修的"对故障隐患集中式批处理,减少分散维修的停机时间"思想,以及时间延迟维修理论,建立生产线的同步维修模型,该模型利用生产线每天停机次数、每次停机时间及检查时发现的缺陷数,计算出合理的生产线检查周期,并以此为依据制定维修计划,实现"提高维修批量,减少生产线停机时间"的目标。最后,实例研究。收集某生产线近十年的故障记录数据,在分析生产流程、设备布局、各设备停机影响的基础上,提出对策指导生产线维修管理。

To solve the problem of long downtime and high cost of automatic production line,group maintenance model is put forward.Firstly,the target function is given,which describes the relation between inspection cycle and total downtime.Secondly,according to the delay time maintenance theory and the idea of group maintenance,namely reducing the total downtime by the means of batch maintenance,group maintenance model is established.Using data such as failure number occurred in production line,and the number of defects identified in PM,the established model can calculate the reasonable inspection cycle.Only with the calculated inspection cycle,the maintenance plan can be outlined,and the target of reducing total downtime by the means of maintenance batch will be realized.Finally,a case study is given.Failures record data in the past decade are collected.Some advices are presented,which is based on the analysis of production flow,equipment layout,and the effect of equipments downtime as well.