对于软包锂电池制造企业，由于设备资产占总资产比例高，设备管理水平的高低直 接影响优质低成本和快速交货目标的达成。设备综合效率是用来考核设备管理水平的重 要指标。设备综合效率越高，证明公司的设备管理能力越强。通过 OEE（Overall Equipment Effectiveness，设备综合效率）的统计和分析能全面暴露企业设备管理中 各个方面的问题，有利于改善设备的使用、维护保养，从而消除浪费、挖掘生产潜力和 提高生产效率。TPM（Total Productive Maintenance，全员生产维护）则是以全系统 的预防维修为过程，全体人员参与为基础，追求生产系统效率的极限为目标，实现设备 OEE 的持续改进的设备保养和维修管理体系。 本文在研究和分析 TPM 设备管理理论的基础上，借鉴推行设备 TPM 管理的企业的成 功经验，结合 A 公司调查和分析的设备管理的实际情况，在 A 公司设备管理中导入设备 TPM 管理，并以 OEE 作为 TPM 管理效果评估的指标。选取了 A 公司四大工序的主要设备 作为研究对象，通过 Andon（安灯）系统对 TPM 实施前的数据进行采集和整理，计算和 分析其设备的 OEE，找出了影响 A 公司 OEE 的最重要两个因素为换型调整和设备故障停 机，并对其进行详细分析。针对换型调整损失采取 SMED（Single Minute Exchange of Die， 快速换模）进行改善；设备故障损失采用自主维护进行改善。有针对性地构建了 A 公司 重要工序设备 TPM 管理系统，提升公司的设备管理水平，确保公司能够制造高质低成本 的产品，满足顾客需求，并为软包锂电池行业企业提供参考借鉴。通过对 TPM 的研究， 在使企业获得经济收益的同时促进了企业文化健康发展，提高了市场占有率。众多国内 软包锂电池企业如果能够运用 TPM 管理，能够扩大锂电池应用场景，促进建立友好型和 资源型社会。 关键词，全员生产维护、设备综合效率、快速换模、安灯系统华南理工大学硕士学位论文 II Abstract For soft-bag lithium battery manufacturer, because equipment assets account for a high proportion of total assets, the level of equipment management directly affects the achievement of high-quality, low-cost and fast delivery goals. The comprehensive efficiency of equipment is an important index for evaluating the level of equipment management. The higher the comprehensive efficiency of equipment, the stronger the equipment management ability of the company. Through OEE (Overall Equipment Effectiveness) statistics and analysis, all aspects of equipment management problems can be fully exposed, which is conducive to improving the use and maintenance of equipment, thereby eliminating waste, tapping production potential and improving production efficiency. TPM (Total Productive Maintenance) is a system-wide preventive maintenance process, based on the participation of all personnel, to pursue the limit of production system efficiency as the goal, to achieve the continuous improvement of equipment OEE equipment maintenance and maintenance management system. Based on the research and analysis of TPM equipment management theory, drawing on the successful experience of enterprises implementing TPM management of equipment, combining with the actual situation of equipment management investigated and analyzed by A company, this paper introduces TPM management of equipment into equipment management of A company, and takes OEE as the evaluation index of TPM management effect. The main equipment of four main processes of A company is selected as the research object. The data before TPM implementation is collected and sorted through Andon system. The OEE of the equipment is calculated and analyzed. The two most important factors affecting OEE of A company are found out, which are type change adjustment and equipment failure shutdown, and the detailed analysis is made. SMED (Single Minute Exchange of Die) is adopted to improve the loss of type change adjustment, and self-maintenance is used to improve the loss of equipment failure. The TPM management system of the important process equipment of A company was constructed to improve the equipment management level of the company, ensure that the company can manufacture high-quality and low-cost products to meetIII customer needs, and provide reference for soft-bag lithium battery industry enterprises. Through the study of TPM, it can make enterprises gain economic benefits, promote the healthy development of corporate culture and increase market share. If many domestic soft-packed lithium battery enterprises can use TPM management, they can expand the application scenario of lithium battery and promote the establishment of a friendly and resource-based society. Key words: Total Production Maintenance; Overall Equipment Effectiveness; Single Minute Exchange of Die; Andon system华南理工大学硕士学位论文 IV 目 录 摘要.........................................................................................................................................I Abstract....................................................................................................................................II 第一章 绪论...............................................................................................................................1 1.1 研究背景......................................................................................................................1 1.2 研究目的和意义..........................................................................................................2 1.2.1 研究目的...........................................................................................................2 1.2.2 研究意义...........................................................................................................3 1.3 国内外研究现状..........................................................................................................4 1.3.1 设备维护、TPM 和 OEE 的关系.........................................................................4 1.3.2 国外研究现状...................................................................................................5 1.3.3 国内研究现状...................................................................................................6 1.4 研究方法和技术路线..................................................................................................7 1.4.1 主要采取的研究方法.......................................................................................7 1.4.2 技术路线............................................................................................................7 1.5 论文内容......................................................................................................................8 第二章 A 公司设备综合效率现状与分析................................................................................9 2.1 A 公司和其产品介绍...................................................................................................9 2.1.1 A 公司介绍........................................................................................................9 2.1.2 产品介绍............................................................................................................9 2.2 A 公司软包锂电芯的生产工艺流程.........................................................................10 2.3 A 公司四大工序关键设备及管理现状.....................................................................11 2.3.1 A 公司四大工序主要生产设备构成..............................................................11 2.3.2 A 公司设备管理相关部门..............................................................................13 2.3.3 A 公司设备相关人员......................................................................................13 2.4 A 公司面临的挑战.....................................................................................................14 2.5 A 公司设备管理存在的问题.....................................................................................15 2.5.1 A 公司 OEE 现状..............................................................................................15 2.5.2 设备管理现场调查.........................................................................................16V 2.5.3 Andon 系统建立分析和评估基础..................................................................18 2.6 A 公司 OEE 现状分析.................................................................................................21 2.6.1 换型调整损失分析.........................................................................................21 2.6.2 设备故障损失分析.........................................................................................23 2.7 导入 TPM 的需求........................................................................................................24 2.8 本章小结....................................................................................................................24 第三章 基于 TPM 的 A 公司设备 OEE 改善.............................................................................25 3.1 基于 TPM 改善换型调整损失....................................................................................25 3.1.1 SMED 方法分析换型调整损失........................................................................25 3.1.2 SMED 改善决策................................................................................................27 3.1.3 设备换型标准化.............................................................................................29 3.1.4 制定设备换型时间作为主要绩效标准.........................................................30 3.2 基于 TPM 改善设备故障损失....................................................................................31 3.2.1 自主维护活动与设备故障损失.....................................................................31 3.2.2 TPM 自主维护活动的广泛宣传与组织保障..................................................33 3.2.3 TPM 自主维护目标的设定..............................................................................34 3.2.4 自主维护的七个阶段和三个主要改善工具.................................................35 3.2.5 制定 TPM 自主维护活动推行计划.................................................................38 3.2.6 A 公司设备自主维护活动..............................................................................40 3.3 本章小结....................................................................................................................43 第四章 基于 TPM 的 OEE 改善效果和保障措施...................................................................45 4.1 基于 TPM 的 OEE 改善效果........................................................................................45 4.1.1 基于 TPM 改善换型调整损失的效果.............................................................45 4.1.2 基于 TPM 改善设备故障损失的效果.............................................................45 4.1.3 基于 TPM 改善设备 OEE 的效果.....................................................................46 4.2 推行 TPM 对 A 公司的影响........................................................................................47 4.3 推行 TPM 的保障措施................................................................................................47 4.3.1 TPM 管理模式固化..........................................................................................47 4.3.2 持续改善活动与 TPM 活动的交互.................................................................49 4.4 本章小结....................................................................................................................49华南理工大学硕士学位论文 VI 结 论.......................................................................................................................................50