基于产品检测的串联多设备预防性维护策略
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摘要
以多设备串联生产流水线作为研究对象,引入设备故障规律的浴盆曲线,提出以设备可靠度作为产品合格检测的时间点,将产品检测考虑至系统总成本中,制定符合设备劣化特性的系统预防性维护计划.根据设备劣化的可靠度计算质量控制时间点,人为地对生产过程中的产品进行合格性检测,进一步提高产品的合格率,判断设备的劣化状态,动态调整维护计划,对达到预防性维护要求的劣化设备进行维护,减少非计划停机与残次品生产造成的延迟时间,实现企业生产线长期运行的最低总成本率,最后通过案例验证了该策略的有效性.
Taking serial production line of multi-device as research object, the bathtub curve is introduced as the device failure rule and it is proposed that the device reliability should be taken as the time point of product qualification inspection and the product inspection cost should be considered as a portion in total system cost rates to make systematic preventive maintenance plan in line with the characteristics of device deterioration. According to the time point of quality control calculated out from the reliability of device deterioration, the qualification inspection of the products in production process is artificially conducted to improve further the proportion of qualified products, judge the deterioration state of the device, adjust dynamic ally the maintenance plan, to carry out the maintenance for the deteriorative device which meets the requirements of device maintenance, reduce the times of unplanned shut down and the time-delay caused by defective article production, realizing the lowest total cost of long-term operation on enterprise production line. Finally, the validity of this policy is verified by means of an actual case.
Taking serial production line of multi-device as research object, the bathtub curve is introduced as the device failure rule and it is proposed that the device reliability should be taken as the time point of product qualification inspection and the product inspection cost should be considered as a portion in total system cost rates to make systematic preventive maintenance plan in line with the characteristics of device deterioration. According to the time point of quality control calculated out from the reliability of device deterioration, the qualification inspection of the products in production process is artificially conducted to improve further the proportion of qualified products, judge the deterioration state of the device, adjust dynamic ally the maintenance plan, to carry out the maintenance for the deteriorative device which meets the requirements of device maintenance, reduce the times of unplanned shut down and the time-delay caused by defective article production, realizing the lowest total cost of long-term operation on enterprise production line. Finally, the validity of this policy is verified by means of an actual case.
引文
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[12] 张民悦,李茗.基于调整因子的弹性周期预防维护模型 [J].兰州理工大学学报,2014,40(6):148-151.
[13] WANG C H.Economic off-line quality control strategy with two types of inspection errors [J].European Journal of Operational Research,2007,179(1):132-147.
[2] STENSTROM C,NORRBIN P,PARIDA A,et al.Preventive and corrective maintenance cost comparison and cost benefit analysis [J].Structure & Infrastructure Engineering,2016,12(5):603-617.
[3] 奚立峰,周晓军,李杰.有限区间内设备顺序预防性维护策略研究 [J].计算机集成制造系统,2005,11(10):1465-1468.
[4] LIU Y,HUANG H Z.Optimal selective maintenance strategy for multi-state systems under imperfect maintenance [J].Annual Reliability & Maintainability Symposium,2010,59(2):321-326.
[5] NOURELFATH M,NAHAS N,BEN-DAYA M.Integrated preventive maintenance and production decisions for imperfect processes [J].Reliability Engineering & System Safety,2015,148:21-31.
[6] ZHANG J,HUANG X,FANG Y,et al.Optimal inspection-based preventive maintenance policy for three-state mechanical components under competing failure modes [J].Reliability Engineering & System Safety,2016,152:95-103.
[7] SETT B K,SARKAR S,SARKAR B.Optimal buffer inventory and inspection errors in an imperfect production system with preventive maintenance [J].International Journal of Advanced Manufacturing Technology,2016,90(1/2/3/4):1-16.
[8] SARKAR B,SAREN S.Product inspection policy for an imperfect production system with inspection errors and warranty cost [J].European Journal of Operational Research,2015,248(1):263-271.
[9] 廖雯竹,潘尔顺,奚立峰.基于设备可靠性的动态预防维护策略 [J].上海交通大学学报,2009,43(8):1332-1336.
[10] 吕文元,郑睿.基于时间延迟维修理论检查模型的比较研究 [J].管理科学,2007,20(1):18-21.
[11] 蔡燕震.基于浴盆曲线规律的公路机电设备维修决策研究 [J].北方交通,2014,37(10):125-128.
[12] 张民悦,李茗.基于调整因子的弹性周期预防维护模型 [J].兰州理工大学学报,2014,40(6):148-151.
[13] WANG C H.Economic off-line quality control strategy with two types of inspection errors [J].European Journal of Operational Research,2007,179(1):132-147.