9 ANPS 全員生產(chǎn)保全 (簡體字)

1、Total Productive Maintenance全 員 生 產(chǎn) 保 全. Total Productive Maintenance 全員消費保全 Meaning of TPM 全員消費保全之意義 A Japanese Kaizen Strategy focus on improving the efficiency of machine to gain the overall profit of the company. 為日本的改善戰(zhàn)略活動之一種，著眼于改良 機器設(shè)備的效率，以提升公司整體的利益。. Total Productive Maintenance 全員消費保全 Featur

2、es of TPM TPM 之特徵 Emphasize overall company efficiency 著重企業(yè)整體的效率化 Achieve Zero Defect, Zero Accident, Zero Shutdown 追求零不良、零災(zāi)禍、零缺點 Involve all departments,Production, R&D, Marketing 包含一切部門，消費、開發(fā)、營業(yè)部門 All employees participation, from CEO to operator 從總經(jīng)理到作業(yè)員均參與 Kaizen by Small Group Activities 以小團隊活動

3、來進展改善. Total Productive Maintenance 全員消費保全 Benefits of implementing TPM TPM 之目的 Reduce shutdown time to deliver product on time 減少停機，交期準(zhǔn)時 Stabilize Machine Capability to assure quality level 穩(wěn)定性能，確保質(zhì)量 Increase Overall Equipment Efficiency to reduce cost 提升效率，降低本錢 Upgrade operation skills to guarante

4、e safety 提升技藝，保證平安 . Total Productive Maintenance 全員消費保全 Level of Maintenance 保全的境界 BM : Breakdown Maintenance 事后保全 PM : Preventive Maintenance 預(yù)防保全 CM : Corrective Maintenance 改良保全 MP : Maintenance Prevention 保全預(yù)防. Total Productive Maintenance 全員消費保全 6 Pillars of TPM TPM六大支柱 Users Maintenance 自主保全

5、Planned Maintenance 方案保全 Case Correction 個別改善 Initial Management 初期管理 Easier Manufacturing 易制設(shè)計 Education Training 教育訓(xùn)練. Total Productive Maintenance全員消費保全 Relationship between Pillars and Levels 支柱與境界之關(guān)連 Breakdown 事后Maintenance 保全Users Maintenance 自主保全Planned Maintenance 方案保全Case Correction 個別改善Edu

6、cation Training 教育訓(xùn)練Initial Management 初期管理Easier Manufacturing 易制設(shè)計Preventive 預(yù)防Maintenance 保全Corrective 改良Maintenance 保全Maintenance 保全Prevention 預(yù)防. Total Productive Maintenance 全員消費保全 6 Major Losses of Machine 設(shè)備六大損失 Equipment Breakdown 缺點損失 Minor Stoppage 瞬停損失 Changeover/Adjustment 換模損失 Defects/

7、Rework 不良損失 Speed Reduction 退化損失 Waiting Operation 等待損失. Total Productive Maintenance全員消費保全 Relationship among Losses, Pillars and Job Function (1/2) 損失、支柱與職務(wù)之關(guān)連(1/2) Losses 損失 Pillars 支柱 Equipment Breakdown 缺點損失Users Maintenance 自主保全Planned Maintenance 方案保全Case Correction 個別改善Education Training 教育訓(xùn)

8、練Initial Management 初期管理Easier Manufacturing 易制設(shè)計Minor Stoppage 瞬停損失Changeover Adjustment 換模損失Defect Rework 不良損失Speed Reduction 退化損失Waiting Operation 等待損失. Total Productive Maintenance全員消費保全 Relationship among Losses, Pillars and Job Function (2/2) 損失、支柱與職務(wù)之關(guān)連(2/2) Pillars 支柱 Job 職務(wù) Users Maintenanc

9、e 自主保全Operator 作業(yè)員Supervisor 線 長Maintenance Technician 保全員Consultant 顧 問Maintenance Engineer工程師Develop Engineer 開 發(fā)Planned Maintenance 方案保全Case Correction 個別改善Easier Manufacturing 易制設(shè)計Initial Management 初期管理Education Training 教育訓(xùn)練. Total Productive Maintenance 全員消費保全 Measures for Equipment 設(shè)備績效衡量目的

10、Overall Equipment Efficiency 設(shè)備總合效率(可動率) Measure of the available, performance and quality efficiency of equipment 衡量設(shè)備的時間、性能及質(zhì)量之效率 Mean Time Between Failures 平均缺點間隔時間 Mean Frequency Of Failure 平均缺點次數(shù) Measure of the reliability of equipment 衡量設(shè)備的可靠才干 Mean Time To Repair 平均修護時間 Measure of the maintai

11、nability of equipment 衡量設(shè)備的維修才干. Total Productive Maintenance 全員消費保全 Definition of OEE(1/2) 設(shè)備總合效率之定義OEE可動率= Equipment Available Efficiency 設(shè)備時間效率 x Performance Efficiency 性能效率 x Quality Efficiency 質(zhì)量效率Equipment Available Efficiency 設(shè)備時間效率: Loss of breakdown 缺點損失 Loss of changeover 換模損失 Loss of insp

12、ection 檢查損失 Loss of waiting 等待損失 . Total Productive Maintenance 全員消費保全 Definition of OEE(2/2) 設(shè)備總合效率之定義 Performance Efficiency 性能效率: Loss of minor stoppage 瞬停損失 Loss of dummy running 空轉(zhuǎn)損失 Loss of speed reducing 退化損失 Quality Efficiency 質(zhì)量效率: Loss of defects 不良損失 Loss of rework 重修損失 Loss of retest 重測損

13、失 . Total Productive Maintenance 全員消費保全 Calculation of OEE 可動率的算法(1/2)(A) Total Time a day 每日時間= 60min分 x 24Hrs小時 = 1440min分(B) Planned Shutdown Time 方案停機時間= 480min分 b1) Break Time 休憩時間= 60min 分 x 2 = 120min分 b2) Preventive Maintenance 預(yù)防保全時間 = 60min 分 x 2 = 120min分 b3) No Order Waiting Time 無定單等待時間

14、 = 60min 分 x 4 = 240min分(C) Production Scheduled Time 消費方案時間(=A-B) = 960min分(D) Unscheduled Down Time 不測停頓時間= 100min分 d1) Breakdown 缺點 = 20min分 d2) Changeover/Set up/Adjustment換模/安裝/調(diào)整=40min分 d3) Tools Change/Inspection 刀具改換/檢查= 30min分 d4) Waiting Operator/Materials 等待人員/資料= 10min分 . Total Productiv

15、e Maintenance 全員消費保全 Calculation of OEE 可動率的算法(2/2)(E) Available Operation Time 有效消費時間(=C-D) = 860 min分 Equipment Available Efficiency 設(shè)備時間效率 ( = E/C = 860/960 ) = 89.6%(G) Total Output Quantity 全部消費數(shù)量( = 1450 pcs個)Ideal Cycle Time 實際周期時間( = 0.5 min分/pc個 ) Equipment Performance /Efficiency 設(shè)備性能效率 =

16、(G x H)/E = 84.3 %Total Rejected Quantity 總不良數(shù)= 200 pcs 個 Equipment Quality Efficiency 設(shè)備品質(zhì)效率 = (G -J)/G = 86.2 % OEE 可動率= F x I x K = 89.6% x 84.3% x 86.2% = 65.1% or 或者 = (G-J) x H/C = 65.1%. Total Productive Maintenance 全員消費保全 What is Users Maintenance 何謂自主保全 The user of equipment is responsible

17、for some basic maintenance activities of equipment 由運用機器設(shè)備的操作者，擔(dān)任從事 一些機器設(shè)備的根本保全任務(wù)之意。. Total Productive Maintenance 全員消費保全 Objectives of Users Maintenance自主保全之目的 Increase the users care on equipment. 提升操作者對設(shè)備的關(guān)懷度 Increase the users capability to operate equipment 提升操作者對設(shè)備的操作才干 Increase the users capa

18、bility to find out the abnormal situation of equipment earlier. 提升操作者能早期覺察設(shè)備異常情況之才干 To increase the reliability and OEE of equipment. 提升設(shè)備的可靠才干及提升設(shè)備的可動率. Total Productive Maintenance 全員消費保全 Seven Steps of Users Maintenance 自主保全展開七步驟1) Initial cleaning and check 初期清掃點檢2) Elimination of sources of con

19、tamination 排除困難發(fā)生源頭3) Establish standards of cleaning and lubrication 作成清掃及光滑基準(zhǔn)4) Implement general inspection and training 實施總點檢及技藝教育5) Implement inspection by user 實施自主點檢6) Implement quality assurance 實施質(zhì)量保證7) Maintain standards and continue improvement 自主維持管理及提升程度.Purpose 目的Learn the teamwork act

20、ivities and leadership skills 學(xué)習(xí)團隊活動及指點技藝Learn the concept of “cleaning means check 學(xué)習(xí) “ 清掃即是點檢 之觀念Learn the safety operation procedure 學(xué)習(xí)平安操作程序Expose the abnormal condition of equipment and correction 找出設(shè)備異常之處及復(fù)原 Total Productive Maintenance 全員消費保全 Step 1 of Users Maintenance (1/2) 自主保全第一步驟(1/2)Ini

21、tial cleaning and check 初期清掃點檢.Main Activities 主要活動 Remove unneeded parts 設(shè)備不要之物移走Clean equipment 清掃設(shè)備Discover abnormal condition 覺察異常之處 * List of difficult cleaning 清掃困難表 * List of unstable condition 不佳形狀表 * List of query 疑惑一覽表 * List of contamination source 污染源頭表Correct the abnormal condition 復(fù)元異常

22、之處 * Red Tag for abnormal condition異常之處貼上膏藥單(紅單) Total Productive Maintenance 全員消費保全 Step 1 of Users Maintenance (2/2) 自主保全第一步驟 (2/2)Initial cleaning and check 初期清掃點檢.Purpose 目的Learn the basic skills of maintenance 學(xué)習(xí)根本保全技藝Learn the corrective skills for abnormal condition 學(xué)習(xí) 矯正異常 之技巧Increase reliab

23、ility of equipment by reducing contamination 減少設(shè)備污染，以提升可靠性Keep equipment always in clean condition to increase maintainability 堅持設(shè)備清潔形狀，以提升保全性Improve equipment to be easier for clean and check 改善設(shè)備使容易清掃及點檢 Total Productive Maintenance 全員消費保全 Step 2 of Users Maintenance (1/2) 自主保全第二步驟(1/2)Elimination

24、 of Difficulties 排除困難發(fā)生源頭.Main Activities 主要活動Eliminate difficult cleaning area 排除清掃困難處所Prevent contamination 防止污染飛散對策Improve the efficiency of clean and check 提升清掃及點檢效率 Total Productive Maintenance 全員消費保全 Step 2 of Users Maintenance (2/2) 自主保全第二步驟(2/2)Elimination of Difficulties 排除困難發(fā)生源頭. Total Pro

25、ductive Maintenance 全員消費保全 One Point - Lesson 每日一課 Purpose 目的 Use as a training tools for operators, technicians and engineer 做為作業(yè)員、維修員、工程師的訓(xùn)練教材 Share and transfer the Kaizen Skills of equipment 分享及傳承對設(shè)備的改善技巧 Key Points for Writing 寫作要點 Short in single page 簡短一頁完成 Better use drawings, picture or dia

26、grams 最好運用 繪圖、照片方式 10 minutes or less for presentation 能在10分鐘內(nèi)講解完成 .Purpose 目的Learn to establish maintenance standards 學(xué)習(xí)本人制定保全規(guī)范Realize the importance of adhering to standards 了解遵守規(guī)范之重要性Maintain basic condition of equipment to prevent deterioration 維持設(shè)備根本條件，防止劣化Apply visual management skills 實施目視管理

27、 Total Productive Maintenance 全員消費保全 Step 3 of Users Maintenance (1/2) 自主保全第三步驟(1/2) Establish Standards of Cleaning and Lubrication 做 成 清 掃 及 潤 滑 基 準(zhǔn).Main Activities 主要活動Develop standards of cleaning and lubrication 開展清掃及光滑基準(zhǔn)Shorten the time of cleaning and lubrication 縮短清掃及光滑時間Visual management fo

28、r easier lubrication 容易光滑之目視化Train the skills of cleaning and lubrication 訓(xùn)練清掃及光滑之技巧 Total Productive Maintenance 全員消費保全 Step 3 of Users Maintenance (2/2) 自主保全第三步驟(2/2) Establish Standards of Cleaning and Lubrication 做 成 清 掃 及 潤 滑 基 準(zhǔn).Purpose 目的Learn the knowledge and skill of checking equipment 學(xué)習(xí)有

29、關(guān)設(shè)備點檢的知識及技巧Learn the skills of restoration and improvement 學(xué)習(xí)設(shè)備復(fù)原及改善技巧More application of visual management skills 目視管理技巧的深層運用Maintain and improve routine check activities to increase reliability of equipment 做好及改良日常點檢活動，以提升設(shè)備可靠性 Total Productive Maintenance 全員消費保全 Step 4 of Users Maintenance (1/2)

30、自主保全第四步驟(1/2) Implement general inspection and training 實 施 總 點 檢 及 技 能 教 育.Main Activities 主要活動Train the inspection skill for each check item. 對每一點檢工程實施點檢技藝教育訓(xùn)練Implement inspection for all check items. 對一切點檢工程，進展點檢活動Continue to discover problem areas and to Kaizen. 繼續(xù)覺察問題及改善Make sure to finish all

31、check items within limited time. 確保能在一定時間內(nèi)完成點檢工程 Total Productive Maintenance 全員消費保全 Step 4 of Users Maintenance (2/2) 自主保全第四步驟(2/2) Implement general inspection and training 實 施 總 點 檢 及 技 能 教 育.Purpose 目的 Train to use “five senses to discover potential problem area. 訓(xùn)練以“五感 來覺察問題癥兆To deploy the Kaiz

32、en experience to other equipment. 將設(shè)備改善閱歷推行到其它的設(shè)備Discover potential problem areas for earlier correction by daily cleaning and inspection activities. 透 過每日清掃及點檢活動，提早覺察潛在問題并矯正 Total Productive Maintenance 全員消費保全 Step 5 of Users Maintenance (1/2) 自主保全第五步驟(1/2)Implement inspection by user 實施自主點檢.Main A

33、ctivities 主要活動Establish daily check list of cleaning and inspection based on standards. 根據(jù)清掃及點檢規(guī)范，作成每日查核表Strictly adhere to implement daily cleaning and inspection. 嚴(yán)厲地遵行每日自主清掃及點檢Strive to achieve the goal of zero rate of breakdown. 努力追求零缺點為目的Take corrective action immediately if necessary 必要時能立刻采取改

34、善措施 Total Productive Maintenance 全員消費保全 Step 5 of Users Maintenance (2/2) 自主保全第五步驟(2/2)Implement inspection by user 實施自主點檢.Purpose 目的 Learn the effects of equipment condition to the process capacity and quality level. 學(xué)習(xí)設(shè)備的情況對制程才干及質(zhì)量程度的影響Learn the importance of adhering to Standard Operation Procedu

35、re and its effect to quality level. 學(xué)習(xí)遵守作業(yè)規(guī)范書對質(zhì)量影響的重要性Review quality assurance capability of equipment. 檢討設(shè)備的質(zhì)量保證才干Try to improve the process capability of equipment. 設(shè)法提升設(shè)備的工程才干 Total Productive Maintenance 全員消費保全 Step 6 of Users Maintenance (1/2) 自主保全第六步驟(1/2) Implement quality assurance 實施質(zhì)量保證.Main Activities 主要活動Enhance the awareness of “ 3 NO Principles of quality assurance 強化質(zhì)量三不原那么的認(rèn)知 * No accept defects 不接受不良品 * No produce defects