提高维修及其可靠性的流程(5)ppt课件

1、The Cargill Maintenance and Reliability Best Practices Workshop嘉吉维修及其可靠性最正确实际研讨会Module Five: Improving Maintenance & Reliability Processes模块五：提高维修及其可靠性的流程Module Five: Topics模块五：主题Defining Efficiency and Effectiveness.定义效率Identification and Correction of Failure CausesPrecision Drivers.失效缘由的识别和纠正自动，准

2、确Practices to Prevent and Eliminate DefectsPrecision Maintenance.防止和消除缺陷精细维修Life Cycle Asset Cost Analysis.设备终身费用分析Defining Efficiency & Effectiveness定义效率Three5Requested Work 20% of Total Work恳求的任务占任务的20% Work Performed任务执行Predictive and Preventive 80% of Total Work预测性和预防性维修占总维修任务的80%PM/PdMResults o

3、f PdM/PMDaily Coordination日常协调Failures/Breakdowns失效/缺点停机Important重要Not urgent不紧急Urgent紧急Important重要Not important不重要Planning任务方案 Scheduling日程安排Weekly schedule每周任务日程安排Job kits任务包 Job Plan Improvement作业方案改良Craftsman feedback技工反响 Work quality checks任务质量检查 Equipment Reliability Improvement设备可靠性提高 Efficie

4、ncy效率 Doing things better and faster. 做事情又快又好 Getting good at what you do. 知道他擅长做什么 Focusing on just the results. 关注结果For example: Changing out pumps quickly but not fixing the cause may be an efficient process, but not necessarily an effective one.例如：快速地将泵改换，但是没有去查找失效缘由，这能够就是效率的一种流程，但是并不是必需的一种效率Eff

5、ectiveness效率Doing the right things better and faster.做正确的事情又快又好Improving the process.改善这种流程For example: Knowing why pumps fail, finding the defects and and fixing the cause. Then, applying the new information to similar situations.例如：知道泵为什么失效，找到缺陷，并且消除由于缘由引起的缺点。那么对于一样的情况，就运用这种新的信息Workflow Process任务流

6、程A system to identify and optimize your business processes.用来识别和优化他的企业的流程的一个系统This is one method of improving processes.它是改善流程的一种方法定义类型紧急任务恳求快速沟通资料搜集功能性同意事件报告非紧急任务恳求评价定义途径要求进展MOC修正方案编制创建和评价包含有平安在内的作业方案调查系统创建工单功能性同意 (PSI)Yes任务执行打印工单r方案工程小组方案维修小组人员技术同意日程安排相关工程曾经有包括平安的作业方案No要求包括平安在内的作业方案No日程安排技术同意手工工单发

7、回给恳求人驳回费用评价根本缘由分析Isnt This the Cargill Quality Process?它是不是嘉吉的质量流程Ref: Charlie Fast, Cargill IncorporatedThe Stages of Maintenance维修的各个阶段Five stages:五个阶段Regressive退步的Reactive消极的Planned方案的Precision准确的Strategic战略的For each stage, there are:对于每个阶段，都有一样的特征Rewards奖励Behaviors行为规范Levels of asset health设备完好等

8、级Force driving change to next stage强迫变革进入下一个阶段阶段奖励行为规范员工工作方式设备完好等级强制变革进入下一个阶段战略的在所有的维修流程中的奖励等级最高，是最佳奖励的候选人可划分为有竞争性的，最低的维修费用，最高的可靠性有灵感的和具有创造性思维的工作方式设备完好等级在行业间最高等级或者在其之上没有下一个阶段。只有可持续的回顾流程来进行不断地提高精确的有有较强的竞争优势来竞争公司的最佳奖项改进了维修流程来避免失效的发生，提高了有效的工时，降低了费用精力充沛，干劲十足，心情舒畅所有设备的等级都得到了提高，并且收到了最大的经济效益更好地理解维修及其可靠性组织的

9、协作并且将它写入企业的经营计划和管理流程里计划的正常的，有一定的竞争优势在坏掉之前进行维修，费用较低生产效率高和忙碌的大多数设备处于稳定状态，有些设备的可靠性得到了提高研究和学习如何识别和消除缺陷消极的经常进行加班加点的维修英雄坏了之后进行维修，产生了高额费用，有一些长期计划照葫芦画瓢，劳神费力，效果不好用于安全和环保的设备的完好等级处于良好的边缘，其余的设备不好加强维修计划及日程安排和预测失效的能力退步的迎合领导作假的维修预算的要求不进行维修活动，更没有长短期的维修计划人人自危，只求自保，精疲力竭，心力憔悴最低的设备完好等级，长期存在相同的失效问题主要的目标集中在企业的商务活动Identif

10、ication and Correction of Failure Causes失效缘由的识别和纠正Identification and Correction of Failure Causes失效缘由的识别和纠正Historical analysis methods.历史的分析方法Availability analysis.有效性分析Work order tracking.工单跟踪Schedule compliance.日程安排的一致性Planning accuracy. 方案编制的准确性Root cause analysis (RCA).根本缘由分析Use of PdM tools to

11、identify failure causes.运用预测性维修工具来识别失效缘由Work type/任务类型Analyzing the type of maintenance work done to determine if it creates maximum value.分析维修任务的类型来断定它能否创建最大的价值Work priority任务优先级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.回想维修任务的优先级来断定工厂的优先顺序和关键性流程关注在正确的设备上Failure history失效历史Reviewing failure data to determine MTBF and other statistics that will drive RCA processes.回想失效资料来断定平均失效期及其它的数据统计来进展根本缘由分析Work Order Tracking工单跟踪Work Order Tracking工单跟踪Review CMMS data and history to determine the accura

13、cy of estimates to actuals and causes of variation.回想计算机维修管理系统的数据资料和历史数据来判别真实任务的准确性和维修任务变量的缘由Planning Accuracy方案的准确性Review weekly schedule compliance to identify causes of schedule breaks.回想每周的维修日程安排的执行一致性来识别日程安排变化的缘由Schedule Compliance日程安排的执行一致性RCA Process Must Become Part of The Site SOP根本缘由分析流程必需

14、变成工厂的规范操作流程的一部分A policy supported by all levels of management must clearly define:一个有一切的各级管理层支持的维修政策必需进展清洗的定义：How a RCA should be conducted.一个根本缘由分析应该如何进展操作When a RCA should be conducted based on threshold criteria.什么时候，一个根本缘由分析应该基于极限规范进展操作Roles and responsibilities of the employees.员工的角色及其责任Managem

15、ents expectations/measures of process.管理层的期望/流程的丈量Evaluation and improvement criteria.评价和改良的规范Conducting a RCA进展一个根本缘由分析Many methods.很多种方法Informal and formal processes.非正式的和正式的流程Many suppliers of software and training.软件和培训的很多的供应商Threshold Criteria Determine When a Formal RCA Adds Value极限规范定义一个正式的根本

16、缘由分析在何时能添加价值 Process loss greater than _ $.工艺损失大于$_Equipment loss greater. than_$设备损失大于$_ EHS exposureEHS问题暴露Critical list component failure.关键部件失效 Chronic items identified by historical analysis.历史数据分析进展的慢性失效 RCA: Four Common Mistakes根本缘由分析：四个通常性错误Using rule-based logic to analyze an event-generate

17、d problem.运用基于惯例的逻辑来分析一个事件产生的问题Not defining the problem completely. 没有将问题完全的定义Using buckets or computer-driven categories.运用组式或者计算机辅助分类的方法Using long narratives that describe the failure event as the soul basis for determining cause.运用长篇累读的方式来描画失效事件作为根本来判别失效缘由Less Structured Approaches几个构造上的阅历Intuiti

18、on直觉力Networking外部资源的利用和共享Experience (expert review teams)阅历专家回想小组Brainstorming头脑风暴Structured Approaches机构上的阅历Process of reactive change analysis.消极的变卦流程的分析Barrier analysis.妨碍分析Event and causal factors analysis.事件及其缘由要素的分析Fishbone or cause & effect diagrams.鱼骨图或者因果图Tree diagrams.树状图RCA Methods根本缘由分析方

19、法International Loss Control Institute国际损失控制协会TapRoot.根本中心RCI - Root Cause Failure Analysis.根本缘由分析协会根本缘由失效分析Apollo - Apollo RCA.阿波罗阿波罗根本缘由分析Think Reliability Cause Mapping思索可靠性因果图Rule vrs Event Based原那么与事件Defines two types of problems对问题的两种类型进展定义Rule based/基于法那么The non-attainment of a clearly establi

20、shed rule or practice. 建立明晰的不胜利失效的原那么或者实际Event Based/基于事件Based on the theory of cause and effect with the potential for multiple causes and effects.基于潜在的因果实际，对于多种因果引起事故进展分析 Cause and Effect因果效应InjuryEffectInjury损伤Effect果CauseEffectFallCauseEffectFallCause因Effect果Fall跌倒Wet FloorCauseEffectWet FloorCa

21、useEffectWet Floor湿地板Cause因Effect果CauseEffectSeal FailCauseEffectSeal FailCause因Effect果Seal Fail密封失效CauseEffectNo MaintCauseEffectNo MaintCause因Effect果No Mint不维修 Valve leakCauseEffectValve leakCauseEffectValve leak阀门走漏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变卦管理失效An Effect is the consequence of a Cause一个果正是一个因引起的When we ask why of a Cause it becomes an Effect当我们向一个因问为什么的时候，它就变成果An Effect exists only if its Causes exist at the same point in Time & Space在一样的时间和空间点里，果只由于因的存在而存在 FireTriangle着火的三个条件Fuel燃料Oxy

23、gen氧气Ignition点火FireFire着火Dropped matchDropped match点燃的火柴落下Oxygen in airOxygen in air空气中有氧气 Rags on the floorbyCaused由引起的 byCondition条件Condition条件Action动作Rags on Floor地板上有碎屑Use of PdM to Identify and Eliminate Defects利用预测性维修来识别和消除缺陷Defect: Equipment or asset life shortening condition.缺陷：导致设备或者资产寿命变短的

24、形状Predictive based cause identification: Identifying defects by using predictive tools.基于预测性维修的缘由识别：运用预测性维修工具来识别缺陷PdM Cause Identification预测性维修缘由识别Identify the cause of failure (defects) and eliminate them.识别失效缺陷的缘由并且消除它们PdM Cause Identification预测性维修缘由识别Practices to Prevent Defects: Precision Mainte

25、nance预止缺陷的实际：准确维修Practices to Prevent Defects防止缺陷的实际Lubrication.光滑Craftsperson skills enhancement.技工的技艺提高Standards and specifications.规范和规范Lubrication PracticesKey Elements光滑实际关键要素Selecting of the right lubricants for the right application.选择正确的光滑剂进展运用Training on the use and application of lubricant

26、s.对光滑剂的正确的运用和运用进展培训Knowing lubricant specifications.懂得光滑剂的规范和性能Understanding and preventing causes of contamination.懂得和防止污染的缘由Lubrication PracticesKey Elements光滑实际关键要素Using an oil and lubricant analysis program.运用光滑油和光滑剂的分析流程Doing receipt inspection of oils and lubricants.在光滑油和光滑剂的接受时进展检查What is Pre

27、cision Maintenance?什么是准确维修？Adopt a “zero defect mentality.采取“零缺陷的思想Establish standards.建立规范Get equipment to comply with standards.对设备要按照规范进展维修Reverse deterioration causes (defects).阻止产生磨损恶化缺陷Create systems to prevent future design defects.创建系统来防止未来的设计缺陷Raise the skills at all levels.提高各种人员的技术程度What

28、is Precision Maintenance?什么是准确维修？续Create an environment were accepting less than the required performance is not tolerated.创建一个这样的维修环境只接受比其技术性能要求好的维修Craftsperson Skill Development技工技艺提高Allocate appropriate training time and funds.分配相应的培训时间及其费用Identify the current minimum standards, if there are any.

29、假设有规范，要识别当前最小的培训规范Identify what skills are missing from the sites needs now & in the future.思索工厂当前和未来的需求，识别工厂短少哪些技艺Determine who will cover this work.确定谁将担任这项任务Create training plans based on individual employee needs.针对不同的员工的不同的需求来创建培训方案Training must be tested, practiced, and formally evaluated.培训必需

30、进展考试，练习和进展正式的评价Evaluate the results of the training.评价培训效果Identify who will be trained.识别哪些人应该被培训Document the process and review it periodically for improvement.归档培训流程并且定期进展回想以利于不断地提高Craftsperson Skill Development技工技艺提高Standards and Specifications规范和规范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.维修任务质量和任务可接受的规范，对于一切的实践的维修行为，都应该进展完善和提高。维修的审核流程应该确保执行的任务质量。一切的返修任务都将接受调查Standards and Specifications规范和规范Precision Balance S

32、tandards For New and Repaired Equipment.对于新的和修缮过的设备要有准确的平衡规范Equipment Vibration Acceptance Standards and Procedures.要有设备振动接受规范及其程序Precision Alignment Standards.准确校正规范Mounted Bearings and Shafting轴承和轴的组装Standards and Specifications规范和规范Mounted Bearings and Shafting轴承和轴的组装Proper Bearing Selection适当的轴承

33、的选择Proper Shaft Specification适宜的轴的规范Proper Shaft Cleaning适宜的轴的清洁Standards and Specifications规范和规范Proper Bearing Selection适当的轴承选择Rolling Element Selection滚动元件的选择Standards and Specifications规范和规范Precision Shaft Selection精细轴选择ASQ Commercial Grade Shafting商贸等级的轴 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避开英制+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; 作为最好的结果，轴的精加工应该控制在10-20微英寸，硬度应在洛式C35或者以上公制单位0.250.50微米Precision Spec. Examples准确维修规范举例Bolt Torque螺栓扭矩Oil Cleanliness油脂清洁Belt Tension皮带涨紧Key Length键槽长度Run out偏摆Pin clearance销间隙Motor base design电动机底座设计Sheave Ali