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研究生: 陳棟良
Chen, Tung-Liang
論文名稱: 成本最小化之設備維護模型
A Cost Minimization Model for the Maintenance of Equipment
指導教授: 利德江
Li, Der-Chiang
學位類別: 博士
Doctor
系所名稱: 管理學院 - 工業與資訊管理學系
Department of Industrial and Information Management
論文出版年: 2012
畢業學年度: 100
語文別: 中文
論文頁數: 69
中文關鍵詞: 計劃性運轉緊急運轉維護週期維護時點微分方程
外文關鍵詞: schedule-based operation, emergency operation, maintenance cycle, maintenance timing
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  • 降低生產成本並確保產品品質乃管理者追求的重要目標,當生產設備操作消耗一段期間後,故障機率會增加,但若能適時維護,可延續設備使用年限並確保產品的生產品質。在全面競爭且要求客製化的市場,客戶需求不穩定,設備須長時間連續運轉以滿足顧客需求,致使設備之維護策略益顯重要。故本文之目的在探討建構維護設備的有效模式並如何維護此一模式且不斷運用,以增加其有效運轉時數相對地減少維護時間及延長生產設備的效期壽命,並提升使用設備的效率,最終達到維護成本花費最少。
    為要增加運轉時數、減少維護時間,在生產過程中使用適當監測儀器設備,周延及適時監視,並能及時、準確地偵測到將發生故障的設備及地方,妥適修護、降低成本;另外,深一層考慮到一個有用的維護管理成本最佳化理論模型,更能降低維護成本。本研究利用關鍵的經驗參數,利用模擬測試找出最佳數據組合,確定最大運轉操作時間、降低維護時數,不僅可以延長其壽命也減少維護成本。在計劃性維護生命週期內的設備,發生故障的狀況及偏差較難掌握情況下,維護費用就會提高,然而,當維修模型進一步改善,使改善過後之設備回復其運轉運作能力,因此初期建立一個遞迴方程式之最佳化模型,利用「改善」方式切實執行維護工作,延長機器設備的生命週期。本研究模式主要參數包括“運轉起動次數”、“運轉時數”、“工作時間”、“維護改善因子”、和“有關溫度限制的設備”。
    最後以模擬方式和微分方法,求得最佳的時間點及維護次數,可降低維修費用或延長運轉時數。並列舉實例說明,找出其總維修次數最少的方式,在本文中取用維護次數可減少2次之數據組合,可提升可用時間六年為最佳,使降低總維護成本為新台幣154,166,020,527元。

    Reduce the production cost and the products quality guaranteed are important goals by the administrator pursues, after while operating and consuming one period of time with production equipment, trouble probability will increase, but if we can do the maintenance just in right time, the service life of apparatus can be extended and the production quality will be in firm. Under the completive, customization market, and the purchase order from the customers are various, the apparatus are continuously, in order to reach customer's requirements, the strategy of how to do the maintenance would be significant. The purpose of this study is to explore and set up an effective model for a timely maintenance schedule and keep this model running constantly, in order to increase the effective running hours and reduce the hours of maintenance of that extends the longevity and improves the efficiency of production equipment, at finally, to have the lowest cost of maintenance.
    In order to increase the running hour and reduce the hours of maintenance, the monitors applied during the producing process appropriately, monitoring in right time can detect the which apparatus and where the break down will be occurred in advance, and do good care of maintenance, reduce the cost, in additional, one more to consider that an effortless application of maintenance theories is useful for managers on cost optimization, the maintenance cost can be reduced more this study aims to use few key empirical parameters utilize the mock test to find out the best data group to determine the best operation hours, reduce the maintenance hours which not only can lengthen their maximum life span but also reduce maintenance costs. Besides, concerned with that within the planned life cycle of the facilities, there can be some unexpected occasions, such as the deviation of demands are hard to control, the maintenance cost would be increased, that the maintenance modules by the models may no longer be robust, in the beginning we here develop an recursive operation time maximization model, the way of “improvement” applied for managing practically the maintenance task. The main parameters of this model included “number of operation starting times”, “operation hours”, “maintenance improvement factor”, and “temperature of equipment”.
    Simulations and differential equations are applied to obtain the optimal time points when the least maintenance cost occurred. The results of the employed example indicate and find out the best way of total maintenance times, and the total times of maintenance can be reduced by two times and upgrade is available for 6 years would be the best make up, and reduce total maintenance costs NT 154,166,020,527.

    摘要 I Abstract II 誌謝 IV 目錄 V 圖目錄 VIII 表目錄 IX 第一章 緒論 1 1.1 研究背景與動機 1 1.2 研究目的 3 1.3 研究範圍、內容、假設與流程 5 1.3.1 研究範圍 5 1.3.2 基本假設 5 1.3.3 研究流程與論述 7 1.3.4 研究內容 7 第二章 文獻回顧與探討 9 2.1 生產設備監視 9 2.2 生產設備維護 10 2.2.1 設備的定義與應用 10 2.2.2 設備維護之定義 11 2.2.3 設備維護管理程序 13 2.2.4 設備運轉 13 2.2.5生產設備運轉 14 2.3 設備維護之策略 15 2.3.1 設備維護之策略分類與定義 15 2.3.2 設備維護之策略分類 17 2.3.3設備維護之沿革 18 2.4維護模型之分析 21 2.4.1 維護作業規劃 22 2.4.2 維護方法 24 2.5 設備運轉 26 第三章 維護模型之建構 27 3.1 符號說明 27 3.2維護改善因子 29 3.3 設備最大運轉時數之模型的構建 30 3.4 問題描述和模型建立 32 第四章 運轉時間之敏感度分析 34 4.1 一般參數的敏感度分析 34 4.2 尺度參數的敏感度分析 39 4.3 形狀參數的敏感度分析 44 第五章 成本最小化模型之實證研究 49 5.1 成本最小化之模型構建 49 5.2 最佳模型之求解 51 5.3 複循環發電廠案例 54 5.3.1 維護時間年限分析 56 5.3.2 可用率因素分析 56 5.3.3 維護成本因素分析 57 第六章 討論與結論 58 參考文獻 60 一、中文部分 60 二、英文部分 61

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