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映电总厂发电部基于TPM的运行维护一体化的方案设计

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摘      要
随着电力体制改革的逐步深入,发电企业面临着市场经济和“厂网分开、竞价上网”的严峻挑战,现有的管理理念和方法已经不能适应环境的变化。因此,发电企业作为一个经济实体,在满足电力生产安全、稳定的前提下,有必要改进和优化管理方法,引进先进管理理论,以适应现代化管理的需要。电力行业的良好效益来自其庞大资产的有效运行,如何在有限的维修费用内使设备更好的运转,创造更好的效益,已成为企业亟待解决的一个难题,这也对企业设备维护管理提出了更高的要求。TPM作为集现代先进设备管理思想于一身的管理理论,已经逐渐被全世界所接受,并且成为企业管理的重要思想,其管理思想在发电厂同样有广阔的应用空间。本文就是在了解映电总厂发电部各电站的运行维护管理现状的基础上,科学地对映电总厂现有的运行维护管理体制进行改革,改变原有的运行和维护分离的状况,探讨如何基于TPM实现运行维护一体化,为其实现“无人值班、少人值守”奠定基础。
论文综述了TPM的发展过程和理论体系,结合映秀湾发电总厂的背景分析了映秀湾发电总厂现有运行管理中存在的问题,提出了解决思路;总结了映电总厂发电部实施基于TPM的运行维护一体化的必要性和可行性;明确了运行维护一体化的内涵和意义;并对运行维护一体化进行方案设计,提出了方案的总体思路;全面概述了运行维护一体化方案的实施内容,主要包括:组织的调整、5S和提案活动的深入开展、点检与巡检的优化、维护工作的规范化、TPM培训体系和考评体系的构建;最后,对设计方案的初步实施结果进行总结。

关键词:发电厂,TPM,自主维护,运行维护一体化
 
ABSTRACT
With the gradual deepening reform of power system, hydropower enterprises are facing the serious challenges of a market economy and the competition on prices and the separation between plants and networks. Existing management theories and methods can't adapt to the change of environment anymore. Therefore, as an economic entity, it is necessary for electricity plants to improve and optimize their operation procedures and introduce advanced management theories to meet the needs of modernized management under the condition of producing safely and steadily.The benefits of power industry come from the effective operation of its huge assets.How to get a better operation of equipments and create a better efficiency in a limited equipment maintenance costs has become a problem to be resolved for the hydropower enterprises and this also has set a higer requirements for the equipment maintenance management.TPM,as a management theory of collection of modern advanced equipment management concepts,has been gradually accepted by the world,and the management concept has a broad application of space in the hydropower enterprises too.This paper made scientific researches on the system reform of the existing operation and maintenance in generation department of the Yingxiuwan hydraulic power plant,changed the situation of the separation of operation and maintenance and probed into how to achieve the integration of operation and maintenance,baced on the understanding of the operation and maintenance management mode of the Yingxiuwan hydraulic power plant.
This paper reviews the development and the theory system of TPM. Combining the background of Yingxiuwan hydraulic power plant, the management problems are analyzed and the solution is presented.It summes up the necessity and feasibility for the Yingxiuwan hydraulic power plant to implement the integratiuon of operation and mainenace baced on TPM and presentes the meaning and significance of the integration. The program of the integratiuon of operation and mainenace is desiged and its content is introduced, including: organizational adjustments, 5S and sponsors activities, the optimization of inspection, the standardization of the maintenance work, TPM training system and the evaluation. At the end, the result of the preliminary implementation of the program is concluded.

Key words: hydropower plant, TPM, autonomous maintenance, the integration of operation and maintenance
 
本文研究方法
本文在研究方法上,坚持理论联系实际,深入企业进行实地调研,采用定性与定量相结合的系统方法对映电总厂基于TPM的运行维护一体化的方案进行设计。
本文作者在课题进展过程中,随同项目组成员到达映电厂发电部的三个直属电站——映秀湾水电站、耿达水电站、渔子溪水电站进行调研,具体了解了电站的运行情况;协助项目组进行5S、提案活动深化的推进活动,其间进行了资料的收集、整理,团队活动培训之前根据培训内容到现场拍摄现场存在的与培训内容相关的问题;在团队活动培训时,认真做好会议记录;编写项目组在电站的工作日志;与电站员工交谈,了解他们对活动开展的想法;返校后,对电站实施基于TPM的运行维护一体化的方案进行了深入的思考和设计。

目      录   43000字
摘      要    I
ABSTRACT    II
目      录    IV
1  绪论    1
1.1 课题研究的目的和意义    1
1.2 课题来源及研究内容    2
1.3 本文研究方法    3
2  TPM理论概述    4
2.1 TPM的起源与发展    4
2.2 TPM的理论体系    5
2.2.1 TPM活动的定义    5
2.2.2 TPM活动的内容    8
2.2.3 TPM的基本理念[12]    10
2.3 TPM在国内外的实施情况    11
2.3.1 TPM在国外的实施情况    11
2.3.2 TPM在国内的实施情况    11
3  映电总厂发电部概况    13
3.1 映电总厂背景介绍    13
3.2 映电总厂发电部管理现状    13
3.2.1映电总厂发电部管理组织概况    13
3.2.2 映电总厂发电部管理现状    16
3.2.3 发电部水电站管理存在问题分析    18
3.2.4 发电部水电站管理存在问题的解决思路    20
4  映电总厂发电部基于TPM的运行维护一体化的方案设计    22
4.1 实施运行维护一体化的必要性可行性分析    22
4.1.1 实施运行维护一体化的必要性分析    22
4.1.2 实施运行维护一体化的可行性分析    24
4.2 实施运行维护一体化的内涵及意义    25
4.2.1 运行维护一体化的内涵    25
4.2.2实施运行维护一体化的意义    26
4.3 实施运行维护一体化的方案设计思路    27
5  映电总厂发电部基于TPM的运行维护一体化的方案实施    29
5.1组织调整    29
5.1.1 运行、维护人员职责职能的调整    29
5.1.2 发电部组织结构调整    30
5.2 5S和提案活动的深入开展    31
5.2.1 实施规划    31
5.2.2前期5S、提案活动进展情况    33
5.2.3 5S的深入开展    36
5.2.4提案活动的深入开展    39
5.3 点检、巡检的优化    43
5.3.1点检、巡检概述    43
5.3.2点检、巡检内容的优化    45
5.3.3点检通道的设置    48
5.3.4 目视管理活动的开展    48
5.4 维护工作的规范化    50
5.4.1 制定维护周期表    51
5.4.2 编写维护工序卡    52
5.4.3 明确维护工作实施流程    52
5.5 培训与考评    55
5.5.1 TPM培训体系    55
5.5.2 TPM考评体系    58
5.6运行维护一体化方案的初步实施效果    60
6  总结    62
致    谢    63
参考文献    64
附录A:维护工序卡标准格式    66

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