提高維修及其可靠性的流程(5)ppt課件

1、The Cargill Maintenance and Reliability Best Practices Workshop嘉吉維修及其可靠性最正確實際研討會Module Five: Improving Maintenance & Reliability Processes模塊五：提高維修及其可靠性的流程Module Five: Topics模塊五：主題Defining Efficiency and Effectiveness.定義效率Identification and Correction of Failure CausesPrecision Drivers.失效緣由的識別和糾正自動，準

2、確Practices to Prevent and Eliminate DefectsPrecision Maintenance.防止和消除缺陷精細維修Life Cycle Asset Cost Analysis.設備終身費用分析Defining Efficiency & Effectiveness定義效率Three5Requested Work 20% of Total Work懇求的任務占任務的20% Work Performed任務執(zhí)行Predictive and Preventive 80% of Total Work預測性和預防性維修占總維修任務的80%PM/PdMResults o

3、f PdM/PMDaily Coordination日常協(xié)調(diào)Failures/Breakdowns失效/缺點停機Important重要Not urgent不緊急Urgent緊急Important重要Not important不重要Planning任務方案 Scheduling日程安排Weekly schedule每周任務日程安排Job kits任務包 Job Plan Improvement作業(yè)方案改良Craftsman feedback技工反響 Work quality checks任務質(zhì)量檢查 Equipment Reliability Improvement設備可靠性提高 Efficie

4、ncy效率 Doing things better and faster. 做事情又快又好 Getting good at what you do. 知道他擅長做什么 Focusing on just the results. 關注結(jié)果For example: Changing out pumps quickly but not fixing the cause may be an efficient process, but not necessarily an effective one.例如：快速地將泵改換，但是沒有去查找失效緣由，這能夠就是效率的一種流程，但是并不是必需的一種效率Eff

5、ectiveness效率Doing the right things better and faster.做正確的事情又快又好Improving the process.改善這種流程For example: Knowing why pumps fail, finding the defects and and fixing the cause. Then, applying the new information to similar situations.例如：知道泵為什么失效，找到缺陷，并且消除由于緣由引起的缺點。那么對于一樣的情況，就運用這種新的信息Workflow Process任務流

6、程A system to identify and optimize your business processes.用來識別和優(yōu)化他的企業(yè)的流程的一個系統(tǒng)This is one method of improving processes.它是改善流程的一種方法定義類型緊急任務懇求快速溝通資料搜集功能性同意事件報告非緊急任務懇求評價定義途徑要求進展MOC修正方案編制創(chuàng)建和評價包含有平安在內(nèi)的作業(yè)方案調(diào)查系統(tǒng)創(chuàng)建工單功能性同意 (PSI)Yes任務執(zhí)行打印工單r方案工程小組方案維修小組人員技術(shù)同意日程安排相關工程曾經(jīng)有包括平安的作業(yè)方案No要求包括平安在內(nèi)的作業(yè)方案No日程安排技術(shù)同意手工工單發(fā)

7、回給懇求人駁回費用評價根本緣由分析Isnt This the Cargill Quality Process?它是不是嘉吉的質(zhì)量流程Ref: Charlie Fast, Cargill IncorporatedThe Stages of Maintenance維修的各個階段Five stages:五個階段Regressive退步的Reactive消極的Planned方案的Precision準確的Strategic戰(zhàn)略的For each stage, there are:對于每個階段，都有一樣的特征Rewards獎勵Behaviors行為規(guī)范Levels of asset health設備完好等

8、級Force driving change to next stage強迫變革進入下一個階段階段獎勵行為規(guī)范員工工作方式設備完好等級強制變革進入下一個階段戰(zhàn)略的在所有的維修流程中的獎勵等級最高，是最佳獎勵的候選人可劃分為有競爭性的，最低的維修費用，最高的可靠性有靈感的和具有創(chuàng)造性思維的工作方式設備完好等級在行業(yè)間最高等級或者在其之上沒有下一個階段。只有可持續(xù)的回顧流程來進行不斷地提高精確的有有較強的競爭優(yōu)勢來競爭公司的最佳獎項改進了維修流程來避免失效的發(fā)生，提高了有效的工時，降低了費用精力充沛，干勁十足，心情舒暢所有設備的等級都得到了提高，并且收到了最大的經(jīng)濟效益更好地理解維修及其可靠性組織的

9、協(xié)作并且將它寫入企業(yè)的經(jīng)營計劃和管理流程里計劃的正常的，有一定的競爭優(yōu)勢在壞掉之前進行維修，費用較低生產(chǎn)效率高和忙碌的大多數(shù)設備處于穩(wěn)定狀態(tài)，有些設備的可靠性得到了提高研究和學習如何識別和消除缺陷消極的經(jīng)常進行加班加點的維修英雄壞了之后進行維修，產(chǎn)生了高額費用，有一些長期計劃照葫蘆畫瓢，勞神費力，效果不好用于安全和環(huán)保的設備的完好等級處于良好的邊緣，其余的設備不好加強維修計劃及日程安排和預測失效的能力退步的迎合領導作假的維修預算的要求不進行維修活動，更沒有長短期的維修計劃人人自危，只求自保，精疲力竭，心力憔悴最低的設備完好等級，長期存在相同的失效問題主要的目標集中在企業(yè)的商務活動Identif

10、ication and Correction of Failure Causes失效緣由的識別和糾正Identification and Correction of Failure Causes失效緣由的識別和糾正Historical analysis methods.歷史的分析方法Availability analysis.有效性分析Work order tracking.工單跟蹤Schedule compliance.日程安排的一致性Planning accuracy. 方案編制的準確性Root cause analysis (RCA).根本緣由分析Use of PdM tools to

11、identify failure causes.運用預測性維修工具來識別失效緣由Work type/任務類型Analyzing the type of maintenance work done to determine if it creates maximum value.分析維修任務的類型來斷定它能否創(chuàng)建最大的價值Work priority任務優(yōu)先級Reviewing the priority of work done to determine if the site priority and criticality processes are focusing the resource

12、s on the right equipment.回想維修任務的優(yōu)先級來斷定工廠的優(yōu)先順序和關鍵性流程關注在正確的設備上Failure history失效歷史Reviewing failure data to determine MTBF and other statistics that will drive RCA processes.回想失效資料來斷定平均失效期及其它的數(shù)據(jù)統(tǒng)計來進展根本緣由分析Work Order Tracking工單跟蹤Work Order Tracking工單跟蹤Review CMMS data and history to determine the accura

13、cy of estimates to actuals and causes of variation.回想計算機維修管理系統(tǒng)的數(shù)據(jù)資料和歷史數(shù)據(jù)來判別真實任務的準確性和維修任務變量的緣由Planning Accuracy方案的準確性Review weekly schedule compliance to identify causes of schedule breaks.回想每周的維修日程安排的執(zhí)行一致性來識別日程安排變化的緣由Schedule Compliance日程安排的執(zhí)行一致性RCA Process Must Become Part of The Site SOP根本緣由分析流程必需

14、變成工廠的規(guī)范操作流程的一部分A policy supported by all levels of management must clearly define:一個有一切的各級管理層支持的維修政策必需進展清洗的定義：How a RCA should be conducted.一個根本緣由分析應該如何進展操作When a RCA should be conducted based on threshold criteria.什么時候，一個根本緣由分析應該基于極限規(guī)范進展操作Roles and responsibilities of the employees.員工的角色及其責任Managem

15、ents expectations/measures of process.管理層的期望/流程的丈量Evaluation and improvement criteria.評價和改良的規(guī)范Conducting a RCA進展一個根本緣由分析Many methods.很多種方法Informal and formal processes.非正式的和正式的流程Many suppliers of software and training.軟件和培訓的很多的供應商Threshold Criteria Determine When a Formal RCA Adds Value極限規(guī)范定義一個正式的根本

16、緣由分析在何時能添加價值 Process loss greater than _ $.工藝損失大于$_Equipment loss greater. than_$設備損失大于$_ EHS exposureEHS問題暴露Critical list component failure.關鍵部件失效 Chronic items identified by historical analysis.歷史數(shù)據(jù)分析進展的慢性失效 RCA: Four Common Mistakes根本緣由分析：四個通常性錯誤Using rule-based logic to analyze an event-generate

17、d problem.運用基于慣例的邏輯來分析一個事件產(chǎn)生的問題Not defining the problem completely. 沒有將問題完全的定義Using buckets or computer-driven categories.運用組式或者計算機輔助分類的方法Using long narratives that describe the failure event as the soul basis for determining cause.運用長篇累讀的方式來描畫失效事件作為根本來判別失效緣由Less Structured Approaches幾個構(gòu)造上的閱歷Intuiti

18、on直覺力Networking外部資源的利用和共享Experience (expert review teams)閱歷專家回想小組Brainstorming頭腦風暴Structured Approaches機構(gòu)上的閱歷Process of reactive change analysis.消極的變卦流程的分析Barrier analysis.妨礙分析Event and causal factors analysis.事件及其緣由要素的分析Fishbone or cause & effect diagrams.魚骨圖或者因果圖Tree diagrams.樹狀圖RCA Methods根本緣由分析方

19、法International Loss Control Institute國際損失控制協(xié)會TapRoot.根本中心RCI - Root Cause Failure Analysis.根本緣由分析協(xié)會根本緣由失效分析Apollo - Apollo RCA.阿波羅阿波羅根本緣由分析Think Reliability Cause Mapping思索可靠性因果圖Rule vrs Event Based原那么與事件Defines two types of problems對問題的兩種類型進展定義Rule based/基于法那么The non-attainment of a clearly establi

20、shed rule or practice. 建立明晰的不勝利失效的原那么或者實際Event Based/基于事件Based on the theory of cause and effect with the potential for multiple causes and effects.基于潛在的因果實際，對于多種因果引起事故進展分析 Cause and Effect因果效應InjuryEffectInjury損傷Effect果CauseEffectFallCauseEffectFallCause因Effect果Fall跌倒Wet FloorCauseEffectWet FloorCa

21、useEffectWet Floor濕地板Cause因Effect果CauseEffectSeal FailCauseEffectSeal FailCause因Effect果Seal Fail密封失效CauseEffectNo MaintCauseEffectNo MaintCause因Effect果No Mint不維修 Valve leakCauseEffectValve leakCauseEffectValve leak閥門走漏Cause因Effect果CauseEffectNot ListedCauseEffectCause因Effect果Not Listed不排出方案CauseEffe

22、ctMOC FailCauseEffectMOC FailCause因Effect果MOC Fail變卦管理失效An Effect is the consequence of a Cause一個果正是一個因引起的When we ask why of a Cause it becomes an Effect當我們向一個因問為什么的時候，它就變成果An Effect exists only if its Causes exist at the same point in Time & Space在一樣的時間和空間點里，果只由于因的存在而存在 FireTriangle著火的三個條件Fuel燃料Oxy

23、gen氧氣Ignition點火FireFire著火Dropped matchDropped match點燃的火柴落下Oxygen in airOxygen in air空氣中有氧氣 Rags on the floorbyCaused由引起的 byCondition條件Condition條件Action動作Rags on Floor地板上有碎屑Use of PdM to Identify and Eliminate Defects利用預測性維修來識別和消除缺陷Defect: Equipment or asset life shortening condition.缺陷：導致設備或者資產(chǎn)壽命變短的

24、形狀Predictive based cause identification: Identifying defects by using predictive tools.基于預測性維修的緣由識別：運用預測性維修工具來識別缺陷PdM Cause Identification預測性維修緣由識別Identify the cause of failure (defects) and eliminate them.識別失效缺陷的緣由并且消除它們PdM Cause Identification預測性維修緣由識別Practices to Prevent Defects: Precision Mainte

25、nance預止缺陷的實際：準確維修Practices to Prevent Defects防止缺陷的實際Lubrication.光滑Craftsperson skills enhancement.技工的技藝提高Standards and specifications.規(guī)范和規(guī)范Lubrication PracticesKey Elements光滑實際關鍵要素Selecting of the right lubricants for the right application.選擇正確的光滑劑進展運用Training on the use and application of lubricant

26、s.對光滑劑的正確的運用和運用進展培訓Knowing lubricant specifications.懂得光滑劑的規(guī)范和性能Understanding and preventing causes of contamination.懂得和防止污染的緣由Lubrication PracticesKey Elements光滑實際關鍵要素Using an oil and lubricant analysis program.運用光滑油和光滑劑的分析流程Doing receipt inspection of oils and lubricants.在光滑油和光滑劑的接受時進展檢查What is Pre

27、cision Maintenance?什么是準確維修？Adopt a “zero defect mentality.采取“零缺陷的思想Establish standards.建立規(guī)范Get equipment to comply with standards.對設備要按照規(guī)范進展維修Reverse deterioration causes (defects).阻止產(chǎn)生磨損惡化缺陷Create systems to prevent future design defects.創(chuàng)建系統(tǒng)來防止未來的設計缺陷Raise the skills at all levels.提高各種人員的技術(shù)程度What

28、is Precision Maintenance?什么是準確維修？續(xù)Create an environment were accepting less than the required performance is not tolerated.創(chuàng)建一個這樣的維修環(huán)境只接受比其技術(shù)性能要求好的維修Craftsperson Skill Development技工技藝提高Allocate appropriate training time and funds.分配相應的培訓時間及其費用Identify the current minimum standards, if there are any.

29、假設有規(guī)范，要識別當前最小的培訓規(guī)范Identify what skills are missing from the sites needs now & in the future.思索工廠當前和未來的需求，識別工廠短少哪些技藝Determine who will cover this work.確定誰將擔任這項任務Create training plans based on individual employee needs.針對不同的員工的不同的需求來創(chuàng)建培訓方案Training must be tested, practiced, and formally evaluated.培訓必需

30、進展考試，練習和進展正式的評價Evaluate the results of the training.評價培訓效果Identify who will be trained.識別哪些人應該被培訓Document the process and review it periodically for improvement.歸檔培訓流程并且定期進展回想以利于不斷地提高Craftsperson Skill Development技工技藝提高Standards and Specifications規(guī)范和規(guī)范Workmanship and work acceptance standards will b

31、e developed for all essential maintenance activities. An audit process will insure the quality of the work performed and the repairs made. All repeat work will be investigated.維修任務質(zhì)量和任務可接受的規(guī)范，對于一切的實踐的維修行為，都應該進展完善和提高。維修的審核流程應該確保執(zhí)行的任務質(zhì)量。一切的返修任務都將接受調(diào)查Standards and Specifications規(guī)范和規(guī)范Precision Balance S

32、tandards For New and Repaired Equipment.對于新的和修繕過的設備要有準確的平衡規(guī)范Equipment Vibration Acceptance Standards and Procedures.要有設備振動接受規(guī)范及其程序Precision Alignment Standards.準確校正規(guī)范Mounted Bearings and Shafting軸承和軸的組裝Standards and Specifications規(guī)范和規(guī)范Mounted Bearings and Shafting軸承和軸的組裝Proper Bearing Selection適當?shù)妮S承

33、的選擇Proper Shaft Specification適宜的軸的規(guī)范Proper Shaft Cleaning適宜的軸的清潔Standards and Specifications規(guī)范和規(guī)范Proper Bearing Selection適當?shù)妮S承選擇Rolling Element Selection滾動元件的選擇Standards and Specifications規(guī)范和規(guī)范Precision Shaft Selection精細軸選擇ASQ Commercial Grade Shafting商貿(mào)等級的軸 Up to 1-1/2 = +0.00/ 0.002 1-9/16 to 2-1/

34、2 = +0.00/ 0.003 2-5/8 to 4.00 = +0.00/ 0.004 Dodge Imperial避開英制+0.000/-0.002; however, for best results, the shaft finish should be held to 10 to 20 micro-inches, and hardness should be 35 Rockwell “C or higher (.25 to .50 micro-meters in metric units)+0.000/-0.002; 作為最好的結(jié)果，軸的精加工應該控制在10-20微英寸，硬度應在洛式C35或者以上公制單位0.250.50微米Precision Spec. Examples準確維修規(guī)范舉例Bolt Torque螺栓扭矩Oil Cleanliness油脂清潔Belt Tension皮帶漲緊Key Length鍵槽長度Run out偏擺Pin clearance銷間隙Motor base design電動機底座設計Sheave Ali