大连理工大学专业学位硕士学位论文
摘
要
A公司是生产航空航天用高强度铝合金板的企业。A公司成立几年来，随着设备产
能的逐步释放，公司对设备的可靠性要求越来越高，生产活动和维修活动中存在的一些
矛盾开始凸显。本文通过研究设备可靠性理论和“零故障”维修管理理论，针对生产和
维修活动中的矛盾点进行分析，以期进一步完善 A公司的维修管理体系。
本文通过整理往年的维修数据，对一线员工日常工作内容按照维修模式进行分类和
统计分析，然后经过数据分析和对比欧美先进维修模式的占比情况，分析找出 A公司设
备管理中存在的问题。另一方面通过研究 A公司的维修综合管理流程，分析找出 A公
司设备计划检修管理上存在的一些问题，并且以设备“零故障”维修管理理论为指导，
挖掘产生问题的原因，提出了维修管理的优化方案，建立设备的可靠运行防护网。为了
实现“零故障”目标，本文从预测性维修（Predictive Maintenance简称 PdM）、预防性
维修（Preventive Maintenance简称 PM）、设备点检和备件管理四个方面进行梳理，通
过数据挖掘和数据分析、5个为什么（5-why）分析法、CAUSE MAP分析法等，再综合
调查结果并建构论证等过程，找出根本问题，力争探索到一条行之有效，适合当前 A公
司自身发展的设备维修管理模式，来发挥人员和设备的最大效能，保证生产受控，安全
平稳，追求“零故障”最终目标。
同时，探索的经验期望能给其他铝行业的设备管理，乃至全国制造行业的设备维修
管理模式提供一定的借鉴作用。
关键词：“零故障”维修理论；设备可靠性；预防性维修；预测性维修；
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A 公司“零故障”设备管理研究
RESEARCH ON EQUIPMENT ZERO FAULT MANAGEMENT
FOR COMPANY A
Abstract
Company A is an enterprise producing high-strength aluminum alloy plates for aerospace.
In the past few years, with the gradual release of equipment capacity, the Company has higher
and higher requirements for equipment reliability, and some contradictions between production
activities and maintenance activities begin to highlight. This paper studies the equipment
reliability theory and "zero failure" maintenance management theory, in order to further
improve the maintenance management system of Company A.
By sorting out the maintenance data of previous years, this paper classifies the daily work
contents of workers according to the maintenance modes and makes statistics on the time of
each items. Then, through data analysis and comparison of the proportion of advanced
maintenance modes in Europe and America, and finds out the problems existing in the
equipment management of Company A. On the other hand, by studying the comprehensive
maintenance management process of Company A, analyzing and finding out the problems
existing in the plan maintenance management, gradually excavating the causes of the problems
under the guidance of the "zero failure" maintenance management theory, and putting forward
the optimization scheme of maintenance management, Establish a reliable operation protection
net for equipment. In order to achieve the goal of "zero failure", this paper combs from four
aspects: Predictive maintenance, Preventive maintenance, equipment routine check and spare
parts management, through data analysis, 5-Why analysis method, Case Map analysis method,
etc. Then synthesize the investigation results and construct the demonstration process, find out
the fundamental problems, and strive to explore an effective equipment maintenance
management mode suitable for the current self-development of Company A, in order to give
full play to the maximum efficiency of personnel and equipment, ensure controlled production,
safety and stability, and strive for the goal of "zero failure ".
At the same time, the exploration experience is expected to provide some reference for the
equipment management of other aluminum industry and even national manufacturing industry.
Key Words：Zero Failure Maintenance Theory；Equipment Reliability；Preventive
Maintenance；Predictive Maintenance
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大连理工大学专业学位硕士学位论文
目录
摘
要.............................................................................................................................I
Abstract ............................................................................................................................. II
1绪论.............................................................................................................................. 1
1.1问题背景与研究意义....................................................................................... 1
1.1.1问题背景................................................................................................ 1
1.1.2研究意义................................................................................................ 2
1.2国内外设备“零故障”管理研究现状........................................................... 3
1.3研究的思路与方法........................................................................................... 4
1.3.1研究的思路............................................................................................ 4
1.3.2研究的方法............................................................................................ 5
1.4论文框架及章节安排....................................................................................... 5
2设备维修管理相关理论.............................................................................................. 7
2.1潜在故障的可预知性....................................................................................... 7
2.2设备“零故障”理论....................................................................................... 8
2.2.1设备“零故障”理念............................................................................ 8
2.2.2设备故障发生的原因和设备故障模式................................................ 9
2.2.3设备“零故障”管理的重点................................................................ 9
2.3可靠性理论..................................................................................................... 10
2.3.1可靠性概念.......................................................................................... 10
2.3.2可靠性维修策略.................................................................................. 11
2.4“零故障”维修和可靠性维修的关系......................................................... 12
3 A公司设备管理现状与问题分析............................................................................ 14
3.1 A公司设备维修的基本情况......................................................................... 14
3.1.1 A公司维修部组织架构...................................................................... 15
3.1.2维修部各区域人员分布...................................................................... 15
3.2基于历年维修数据的问题发现..................................................................... 16
3.2.1 A公司维修模式的占比...................................................................... 18
3.2.2基于预测性工具的设备保养问题...................................................... 19
3.2.3有效点检不足的问题.......................................................................... 21
3.2.4维修活动中等待时间长的问题.......................................................... 22
3.2.5备件质量的问题.................................................................................. 23
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