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研究生: 傅俊凱
Chun-Kai Fu
論文名稱: 設備保養排程最佳化之探討 -以麵粉生產工廠為例
Equipment Maintenance Schedule Optimization -The Flour Plant Case Study
指導教授: 鄭明淵
Min-Yuan Cheng
口試委員: 曾仁杰
Ren-Jye Dzeng
楊亦東
I-Tung Yang
學位類別: 碩士
Master
系所名稱: 工程學院 - 營建工程系
Department of Civil and Construction Engineering
論文出版年: 2017
畢業學年度: 105
語文別: 中文
論文頁數: 87
中文關鍵詞: 人工智慧(AI)生物共生演算法(SOS)維護保養排程最佳化線性規劃
外文關鍵詞: Artificial Intelligence (AI), Symbiotic Organisms Search(SOS), Service maintenance scheduling, Optimization, routine scheduling
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  • 台灣近年來工廠型式已逐漸以機械設備代替勞力密集的型態,隨著工廠設備增加,保養標準流程更顯的重要。由於傳統的設備保養模式往往採用「反應式維護」(Breakdown Maintenance),亦即被動的等待設備發生異常的狀況時再趕緊進行維護,如此的作法就如同人的身體一樣,如果沒有事前的預防,發生狀況後往往會洐生更多其他的問題,而造成總成本大量的提高。
    隨著相關管理知識的提升,近年的設備保養模式已逐漸採用「預防式維護」(Preventive Maintenance)的觀念,定期的保養、紀錄並參考設備系統的狀況修正其保養週期,以有效延緩設備機能提前喪失。但即便工廠管理人員有如此觀念,在實務操作上仍會因傳統人工排程時某些時間需求人力高低峰值過大,導致人力不足而造成排程混亂,到最後逐漸又回到被動式維護的狀況。
    有鑑於此,本研究以某麵粉工廠的製程設備保養排程為例,將依工廠內各項製程設備維護保養週期及維護保養所需的時間,利用二套不同最佳化程式的執行,找尋最佳的排程時間,使每日的需求人力趨於平均,而不致產生忽高忽低的狀況。管理人員也能更準確掌握到人力資源的調配,進而減少人力成本支出。為驗證本案例研究成果,將以某麵粉廠的排程結果與原先人工排程的模式作比較,完成後再針對最佳化程式彼此驗證,以確認最佳化程式的成果是否為最佳解,並可確實達到預期的效果及實際運用。若修正部份參數,未來也可適用在營建設備機械保養排程及其他領域上,並幫助決策者在掌握到相關資訊後可節省更多不必要的人力成本及非預期的設備故障保養支出。


    For the past few years, Taiwanese manufacturing industry with advanced mechanical equipment replaced the labor-intensive process. The use of industrial equipment is increasing, which impact also the importance of the maintenance standard process. The "Breakdown Maintenance" is used as a traditional equipment maintenance standard, which consist to intensify the maintenance process when abnormal situation incurred. This practice is compared as a human body when no prior prevention was set up, the occurrence of the situation will often result to more and bigger problems, and finally conclude into a higher cost in total expense.
    With the improvement of relevant management knowledge in recent years, the equipment maintenance process of has gradually adopted the concept of "preventive maintenance" to regularly maintain, record and refer the equipment system, in order to correct the maintenance cycle to effectively extend the equipment function by prevent early malfunction. Even if the factory management staff have such concept, however, the practical operation will still be due to the traditional scheduling process, when the demand for manpower is too large or low, resulting in lack of resources caused by mismanagement of schedule, and finally returned to the passive maintenance of the situation.
    Thus, this research includes a process of equipment maintenance schedule of a flour factory as an example, in accordance with the factory equipment maintenance cycle and required maintenance time. The implementation of two different optimization programs was used to find the best scheduling time, and calculate the average daily demand of human labor, in order to stabilize the productivity according to the situation. Managers can accurately grasp the deployment of human resources, by applying this method to reduce the labor cost. To verify the result of this case study, the scheduling result of the flour factory will be compared with its original manpower scheduling model. Once completed, the best solution will be chosen depending on the result of each optimization program and confirmed by the desired results, then put in practical use. If some parameters are adjusted, it can also be applied to the implementation of construction equipment maintenance schedule or other area. Therefore, it can help also decision-makers to avoid unnecessary waste of manpower, unexpected equipment failure and prevent maintenance expenditure.

    第1章 緒論 1.1 研究動機 1.2 研究目的 1.3 研究方法與流程 1.3.1 研究方法 1.3.2 研究流程 1.4 論文架構 第2章 文獻回顧 2.1 工廠製程設備概況 2.1.1 麵粉生產標準流程 2.1.2 本案例麵粉製程設備概況 2.2 設備維護機制 2.3 LINGO 12.0 2.4 生物共生演算法(SOS) 第3章 模式建構與求解方法 3.1 問題描述 3.2 模式建立 3.3 參數定義、決策變數及限制式 3.3.1 假設條件 3.3.2 參數定義及決策變數 3.3.3 目標函數及限制式 3.4 求解環境與方法 3.4.1 作業環境及分析方法 3.4.2 輸入參數及輸出變數 3.5 小結 第4章 案例分析與結果 4.1 人工排程法 4.2 最佳化程式測試(LINGO 12.0) 4.2.1 LINGO 12求解測試 4.2.2 LINGO 12求解後週期排程結果 4.3 最佳化程式測試(生物共生演算法SOS) 4.3.1 SOS生物共生演算法求解測試 4.3.2 生物共生演算法(SOS)求解後週期排程結果 4.4 案例分析結果 4.5 類似案例參考使用方式及限制 第5章 結論與建議 5.1 結論 5.2 建議 參考文獻 附錄A 附錄B

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