生產(chǎn)部門tpm全面生產(chǎn)性維護(hù)課件

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ProcessCertificationTPMQCPCRootCause/CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinicActivityTotalProductiveMaintenanceACEManufacturingQualifyingLevel

1ProcessTPMQCPCRootCause/Se2

程序驗(yàn)證全面性生產(chǎn)維護(hù)質(zhì)量診斷程序圖表根本原因修正行動(dòng)減少生產(chǎn)準(zhǔn)備標(biāo)準(zhǔn)化作業(yè)防誤措施市場反饋分析6S質(zhì)量診斷行動(dòng)全面生產(chǎn)性維護(hù)ACE生產(chǎn)部門合格水平

2程序驗(yàn)證全面性生產(chǎn)質(zhì)量診斷程序根本原因減少生產(chǎn)標(biāo)準(zhǔn)化防誤3TotalProductiveMaintenanceisanequipmentmanagementstrategythatimprovesequipmentefficiency.全面生產(chǎn)性維護(hù)是一種設(shè)備管理策略以提高設(shè)備效率。Or,inotherwords...Treatingtheequipmentlikeitisyourown!或者，換句話說…….對(duì)待設(shè)備就象它是你自己的一樣！TPM全面生產(chǎn)性維護(hù)3TotalProductiveMaintenance4TPMKeyConceptTPM的重要概念Leftneglected...EquipmentBreaksDown如果不重視…設(shè)備很快就會(huì)壞TPM’sfocusistopreventproblemsbeforeequipmentbreaks.TPM的焦點(diǎn)是要在設(shè)備出故障以前防止問題出現(xiàn)。Inthepast,maintenancefocused

on

fixingequipmentafteritbroke.過去，維護(hù)工作總是集中在設(shè)備壞了以后對(duì)其進(jìn)行修理。4TPMKeyConceptTPM的重要概念Left5TotalProductiveMaintenance

isaNewWayofWorking

全面生產(chǎn)性維護(hù)是一種全新的工作方式TPMAttitude:TPM態(tài)度：“Weareallresponsibleforourequipment.”“我們所有人對(duì)我們的設(shè)備負(fù)責(zé)。”O(jiān)ldAttitude:過去的態(tài)度：“Ioperate,youfix.”“我操作，你修理?！薄癐fix,youdesign.”“我處理，你設(shè)計(jì)?！薄癐design,youoperate.”“我設(shè)計(jì)，你操作。”5TotalProductiveMaintenance6Afailureisjustthetipoftheiceberg!故障只是冰山的一個(gè)小尖！HiddenDefects隱藏的問題Failures故障Wear,play,slackness,leakage,dust,dirt,corrosion,deformation,adherenceofrawmaterials,surfacedamage,cracking,overheating,vibration,noise,andotherabnormalities.磨損、松馳、泄露、灰塵、污垢、腐蝕變形、原材料粘黏、表面磨損、裂縫、過熱、震動(dòng)、噪音及其它不正常現(xiàn)象。TipoftheIceberg

冰山的頂端6AfailureisjusttheHiddenF7TypicalCausesofMachineBreakdown

典型的機(jī)械故障原因Failuretoaddoil.沒有加油Gritandchipsinrevolvingorslidingparts旋轉(zhuǎn)或滑動(dòng)零件中的砂礫和碎片Contaminationofsensors,contactsandConnectors傳感器、觸敏器、連接器污染Dirtanddustoncoolingfan冷卻風(fēng)扇上有灰塵和污垢ComponentFailure組件失靈Iwonderwhat’sgoingtofailnext?我在想下面還會(huì)出什么問題呢？7TypicalCausesofMachineBre8TPMTechniquesTPM技術(shù)NormaloperatingRange正常操作范圍Danger!危險(xiǎn)！SimplifyandDocumentTPMActivities.簡化并記錄TPM行動(dòng)Usevisualtechniquestoindicatewhat’sright/what’swrong.運(yùn)用直觀技術(shù)來演示什么是對(duì)的/什么是錯(cuò)的。PMCompleted?生產(chǎn)性維護(hù)完成了嗎？Pressuregage壓力計(jì)Sightglass視鏡Arrowsformotorrotationandfluidcirculation馬達(dá)旋轉(zhuǎn)和潤油指示箭頭markingsforsparepartsandfluids.備用零件和潤滑油記號(hào)MakingPMdevicesmoreaccessible.使生產(chǎn)性維護(hù)設(shè)備更容易獲得Filters,fittingsmademoreaccessible過濾器、各種裝置Transparentpanelstofacilitateinspection明了易讀的儀表盤便于檢查8TPMTechniquesTPM技術(shù)Normalop9TPMBenefitsTPM的益處Reducedmaintenancecosts減少維護(hù)費(fèi)用Breakdownmaintenanceis10timesmorecostlythanplannedmaintenance故障維修費(fèi)用是有計(jì)劃進(jìn)行維護(hù)費(fèi)用的10倍以上Enhancedsafety提高安全性Findexposedwires,openbelts,missingguards,loosehardware發(fā)現(xiàn)暴露在外的電線、松開的安全帶、缺少防護(hù)、松開的部件Reducedwaste減少浪費(fèi)Preventslossoflubricant,compressedair防止?jié)櫥?、壓縮空氣的浪費(fèi)Improvedquality提高品質(zhì)Equipmentmorecapableofholdingtolerance設(shè)備抗性增強(qiáng)Lessdowntime,longerlife縮短停工時(shí)間，壽命更長9TPMBenefitsTPM的益處Reducedma1012TPMQualifyingActivitiesACEElementAwarenessTrainingLockOut/TagOutawarenesstrainingavailableforallemployees(withannualrefresher)OperatorsofhighhazardequipmentinformedofmachinespecifichazardsAssessmentofmachinespecificsafeguarding(SP-008)issuesLockOut/TagOutEquipmentAvailableReviewOnlyActionItemsAssessallEquipmentA,B&CImplementwrittenLockOut/TagOutprocedureWalkaroundsafetycheckon100%ofA/BequipmentPMSchedulefor100%ofA/BequipmentCleaningon100%ofA/BequipmentTrackdowntimehistoryToptendowntimeequipmentidentified1012TPMQualifyingActivities1112項(xiàng)TPM合格行動(dòng)ACE內(nèi)容認(rèn)知培訓(xùn)鎖定/標(biāo)識(shí)認(rèn)知培訓(xùn)，針對(duì)所有員工（每年的復(fù)習(xí)進(jìn)修者）告知高危險(xiǎn)設(shè)備操作員有關(guān)機(jī)器的詳細(xì)危險(xiǎn)機(jī)器的特殊防護(hù)措施（SP-008）問題評(píng)估可用的鎖定/標(biāo)識(shí)設(shè)備僅用于檢查行動(dòng)內(nèi)容評(píng)估所有A,B&C類設(shè)備完成寫好的鎖定/標(biāo)識(shí)程序所有A/B類設(shè)備的安全巡查所有A/B類設(shè)備的生產(chǎn)性維護(hù)進(jìn)度表清潔所有A/B類設(shè)備追溯停工歷史確認(rèn)的十大停工設(shè)備1112項(xiàng)TPM合格行動(dòng)ACE內(nèi)容認(rèn)知培訓(xùn)僅用于檢查行12PURPOSEofLockout/Tagout鎖定/標(biāo)識(shí)的目的Topreventyouorsomeoneelsefrominadvertentlyturningapowersourceonandcausingapotentialinjuryorevendeath.以防你或它人意外開動(dòng)電源而造成可能的傷害甚至死亡Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查12PURPOSEofLockout/TagoutTo13LockoutDevice鎖定設(shè)備Alockorotherdevicethatutilizesapositivemeans,toholdanenergyisolatingdeviceinasafepositionandtherebypreventingtheenergizingofamachineorpieceofequipment.一把鎖或其它設(shè)備，用于使電源設(shè)備隔離裝置處于一安全的狀態(tài)，以防止機(jī)器或設(shè)備的一部分帶電。Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查13LockoutDevice鎖定設(shè)備Alockor14TagoutDefinition標(biāo)識(shí)的定義

Theprocessofsecurelyfasteningatagorprominentwarningsigntoindicatethatboththeenergyisolatingdeviceandtheequipmentbeingcontrolled,mustnot

beoperated.是將一標(biāo)簽或明顯的警告標(biāo)志緊附于設(shè)備上以表明不能對(duì)電源隔離設(shè)備及處于控制下的設(shè)備進(jìn)行操作。Thetagwillalsoincludethenameofthepersonwholockedouttheequipment.該標(biāo)簽應(yīng)有鎖定該裝置的人的名字。Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查14TagoutDefinition標(biāo)識(shí)的定義The15WARNING警告NEVERACCEPTLOCKOUTSKEYSFROMANYONE.決不要從它人處接受鎖定設(shè)備的鑰匙。THEASSOCIATERESPONSIBLEFORAPPLYINGTHELOCKORTAGISTHEONLYPERSONAUTHORIZEDTOREMOVETHELOCKORTAG.唯有經(jīng)授權(quán)負(fù)責(zé)運(yùn)用鎖或標(biāo)簽的人員可以拿掉該鎖或標(biāo)簽。Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查15WARNING警告NEVERACCEPTLOCKO16ACTIONITEM1:AssessAllEquipment

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備By“Equipment”wemeananymachinethatwasacapitalexpenseandhasadepreciativevalue.Oranymachinethatisimportanttoyourcell.所謂“設(shè)備”是指任何花費(fèi)了資金并會(huì)貶值的機(jī)器?；蛉魏螌?duì)你的部門重要的機(jī)器。WeCategorizeallEquipmentbasedonhowUniqueandCriticalitistoensurewefocusattentionontherightequipmentfirst.Payspecialattentiontobottleneckequipment.我們根據(jù)設(shè)備的獨(dú)特性和重要性對(duì)所有設(shè)備進(jìn)行分類，以確保我們的注意力優(yōu)先放在正確的設(shè)備上。對(duì)瓶頸設(shè)備給予特殊的關(guān)注。Equipment設(shè)備16ACTIONITEM1:AssessAllEq17CategoryA:

Criticalequipmentforwhichanalternatemachineisnotfeasible,because:A類：不能用其它設(shè)備替代的關(guān)鍵設(shè)備，因?yàn)椋篘oalternateexists,or無替代設(shè)備，或Thealternateisusuallyunavailableduetoutilization,or該替代設(shè)備通常正被使用而不能獲得，或Itwouldbetoocostly/timeconsumingtotransitiontothealternate太貴/需花太多時(shí)間進(jìn)行替換CategoryC:EquipmentforwhichitisrelativelyeasytofindareplacementoralternateC類：相對(duì)容易用其它設(shè)備替代的設(shè)備Includesmostoff-the-shelfequipment包括最常用的設(shè)備Typicallycost<$2,500費(fèi)用低于$2,500Standardspareparts(likedrivemotors)areavailableoff-the-shelf可獲得的常用標(biāo)準(zhǔn)備件（如驅(qū)動(dòng)馬達(dá)）CategoryB:

Allotherequipment/machinesB類：所有其它設(shè)備/機(jī)器ACTIONITEM1:AssessAllEquipment(cont.)

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）17CategoryA:Criticalequipme18Inadditiontomachinecategory,createatablelistingallmachinesandadditionalcategories,suchas:

除了機(jī)器分類，還應(yīng)作一表格列出所有機(jī)器和附加類別，如：Yearofmanufacture產(chǎn)品的生產(chǎn)年份Typeofmachine?Condition?(Good/Fair/Poor)機(jī)器類型？狀況？（好/一般/差）DoesOperatorPMprocessexists(Hasaservicecardbeencreated?)是否有操作員生產(chǎn)性維護(hù)程序（是否有服務(wù)卡？）DoesMaintenancePMprocessexist(Doesawrittenmaintenancetasklistexist?)是否有維護(hù)生產(chǎn)性維護(hù)程序（是否有記錄的維護(hù)任務(wù)表？）Hasthemachineundergoneinitialcleaning?機(jī)器是否經(jīng)過最初的清潔？HasmachinebeenassessedforsafeguardingperSP008?(EH&Sitems)機(jī)器是否經(jīng)過安全裝置SP008評(píng)估？（EH&S項(xiàng)）ACTIONITEM1:AssessAllEquipment(cont.)

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）18Inadditiontomachinecateg19PossibleCategories:可能的分類：Good:

Equipmentwhichretainsallofit’soriginalfunctions,accuracyandreliability.好：設(shè)備保持所有原來的功能，精確并可靠。Average:Equipmentwhichhaslostsomeofit’soriginalfunctionsoraccuracy.It’soutputnormallymeetstherequiredspecifications.一般：設(shè)備喪失了一些最初的功能或精確度。其產(chǎn)品符合要求的規(guī)范。Poor:

Equipmentwhichisnolongeraccurateorreliable.Inordertoproduceacceptableoutput,thisequipmentrequiresoperatorinterventionwellbeyondtheoriginallevel.差：設(shè)備不再精確或可靠。為了生產(chǎn)出可接受的產(chǎn)品，要求操作員對(duì)設(shè)備進(jìn)行超出原有水平的干涉。ACTIONITEM1:AssessAllEquipment(cont.)

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）19PossibleCategories:ACTIONI20ACTIONITEM2:WriteMachine-Specific

LockoutProcedures

LockoutproceduresmustbewrittenandimplementedforeachmachineGeneralproceduresareineffectforSullairProceduresneedtobewrittenjointlywithfacilitiesmaintenance20ACTIONITEM2:WriteMachine21行動(dòng)內(nèi)容2:將特殊鎖定程序?qū)懺跈C(jī)器上鎖定程序必須寫在每臺(tái)機(jī)器上并予以執(zhí)行一般程序適用于壽力公司程序必須與設(shè)備維護(hù)共同寫下來21行動(dòng)內(nèi)容2:將特殊鎖定程序?qū)懺跈C(jī)器上鎖定程序必須寫在22

ACTIONITEM3/4:

OperatorWalkaroundand PMScheduleon100%A/BOperatorPMdefinedfor100%ofCategoryAandBmachinesAbookorsheetexistswhichdefinesthedaily/weekly/monthlyOperatorPMtasksIncludesafetyequipmentoperation(guards,limitswitches,etc.)inOperatorPM.OperatorPMconductedfaithfully(1monthpriortoaudit)onallEquipmentforwhichitisdefined.Rev:BRevisionDate:3/25/98OperatorPreventiveMaintenanceServiceCardMachine:OkumaLC-30,4Axis,BT#3054DailyPMTasks1.

Checkrunningsight.2.

CheckandfillWaylube:Vactra2.3.

Checktrampoilandscrounger.Emptytrampoilifrequired.4.

Checkandfillcoolant:PML9333.WeeklyPMTasks:DoDaily

tasksand

thefollowing:1.

Checkandfillspindlelube:DTE24.2.

Checkandfillairlubricator:DTE24.(Shutoffanddrainairtofill)3.

Checkmotorfanfilter(Changeifnecessary):Cat.#030058.4.

Checkandfillhydraulictank:DTE24.5.

Checkrollfilter(Changeifneeded):Cat.#027793.MonthlyPMTasks:

Doall

tasksonthissheet.1.

Greasechuckfittings,1shot.2.

Grease1fitting,2shots,bothturrets.3.

Cleanairfilter.4.

Changeairfilter:Cat.#021183.22ACTIONITEM3/4:OperatorW23

行動(dòng)內(nèi)容3/4:

操作員巡查和 所有A/B類設(shè)備的PM進(jìn)度表操作員PM定義為所有A、B類機(jī)器應(yīng)有寫明了操作員每日/周/月的PM任務(wù)的書或表包括安全設(shè)備（防護(hù)裝置、限定電閘等）操作員嚴(yán)格地按要求對(duì)所有設(shè)備進(jìn)行生產(chǎn)性維護(hù)（在審查前一個(gè)月）Rev:BRevisionDate:3/25/98OperatorPreventiveMaintenanceServiceCardMachine:OkumaLC-30,4Axis,BT#3054DailyPMTasks1.

Checkrunningsight.2.

CheckandfillWaylube:Vactra2.3.

Checktrampoilandscrounger.Emptytrampoilifrequired.4.

Checkandfillcoolant:PML9333.WeeklyPMTasks:DoDaily

tasksand

thefollowing:1.

Checkandfillspindlelube:DTE24.2.

Checkandfillairlubricator:DTE24.(Shutoffanddrainairtofill)3.

Checkmotorfanfilter(Changeifnecessary):Cat.#030058.4.

Checkandfillhydraulictank:DTE24.5.

Checkrollfilter(Changeifneeded):Cat.#027793.MonthlyPMTasks:

Doall

tasksonthissheet.1.

Greasechuckfittings,1shot.2.

Grease1fitting,2shots,bothturrets.3.

Cleanairfilter.4.

Changeairfilter:Cat.#021183.23行動(dòng)內(nèi)容3/4:操作員巡查和24MakeOperatorPMeffective:Usea“Visibleat-a-glance”system(Suchasacolor-codedPMStatusboard)withinthecelltoindicatetheactualstatusof“OperatorPM”tasks.MustbeeasytounderstandNobookorfoldertoread

ACTIONITEM3/4:

OperatorWalkaroundand PMScheduleon100%A/B (cont.)24MakeOperatorPMeffective:25使操作員進(jìn)行有效的生產(chǎn)性維護(hù):使用一眼就能看見的系統(tǒng)(如使用顏色代碼PM狀態(tài)板)在單元中表明“操作員PM”任務(wù)的實(shí)際狀態(tài)必須容易理解無需翻書或文件夾行動(dòng)內(nèi)容3/4:

操作員巡查和 所有A/B類設(shè)備的PM進(jìn)度表（待續(xù)）25使操作員進(jìn)行有效的生產(chǎn)性維護(hù):行動(dòng)內(nèi)容3/4:操作員26CosmeticCleaning禁止化裝品Yougetabetterlookingpieceofequipmentasabenefitbutnotastheonlyobjective你可以使機(jī)器看起來更漂亮，但這不是唯一的目的Youcleantoimproveamachine’sperformance-notitsappearance清潔是為提高機(jī)器的性能-而不是外表CleantoInspect清潔以檢查InspecttoDetect檢查以發(fā)現(xiàn)DetecttoCorrect發(fā)現(xiàn)以改正ACTIONITEM5:

InitialInspect/Clean100%A/B

行動(dòng)內(nèi)容5：初步檢查/清潔所有A/B類設(shè)備26CosmeticYougetabetterlo27Accessiblecomponentscleaned,inspectedandrepaired可用的部件已清潔、檢查和修好PMdocumentationisreviewed/updatedPM文件已檢查/更新Basicimprovementsareincorporatedtoimprovemaintainabilityandvisual基本的改進(jìn)用于提高可維護(hù)性和形象operatingcondition操作環(huán)境Howaboutthat.

Ididn’tevenknow

therewasa

greasefittinghere!那個(gè)怎么樣。我甚至不知道這兒還有個(gè)油脂裝置！ACTIONITEM5:

InitialInspect/Cleaning100%A/B(Cont.)

行動(dòng)內(nèi)容5：初步檢查/清潔所有A/B類設(shè)備（待續(xù)）27Accessiblecomponentscleane28Usedowntimetrackingresultstodeterminethetoptendowntimeequipment.根據(jù)停工追溯結(jié)果來決定十大停工設(shè)備ACTIONITEM7:

TopTenDowntime

行動(dòng)內(nèi)容7：十大停工設(shè)備ParetoChartPareto圖表28Usedowntimetrackingresult29Whatisnext?

下一步是什么？CompleteTPMtrainingofyourworkgroupbyMarch7,20012001年3月7日前你的工作組應(yīng)完成TPM培訓(xùn)BeforetheendofFebruary,lookforagroupwiseannouncementofa“Driver’s”MeetingtodiscussthenecessaryresourcesandlogisticsforcompletingqualifyingTPMactivities在2月底以前，宣布召開“領(lǐng)導(dǎo)層”會(huì)議，討論必要的資源和后勤以幫助完成取得合格資格的TPM行動(dòng)29Whatisnext?

下一步是什么？Complet30

Wewantacompanythatreverespeoplewhodesign,buildandmaintainthingsthatneverbreak,ratherthanpeoplewhofixthingsthatbreak.

GeorgeDavid UTCChairmanandCEO我們希望公司尊敬那些設(shè)計(jì)、建造并維持不會(huì)壞的東西的人們，而不是那些修理會(huì)壞的東西的人們。

GeorgeDavid UTCChairmanandCEOSummary小結(jié)30Summary小結(jié)31TotalProductiveMaintenance

全面生產(chǎn)性維護(hù)Manufacturing

生產(chǎn)部31TotalProductiveMaintenance32

ProcessCertificationTPMQCPCRootCause/CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinicActivityTotalProductiveMaintenanceACEManufacturingQualifyingLevel

1ProcessTPMQCPCRootCause/Se33

程序驗(yàn)證全面性生產(chǎn)維護(hù)質(zhì)量診斷程序圖表根本原因修正行動(dòng)減少生產(chǎn)準(zhǔn)備標(biāo)準(zhǔn)化作業(yè)防誤措施市場反饋分析6S質(zhì)量診斷行動(dòng)全面生產(chǎn)性維護(hù)ACE生產(chǎn)部門合格水平

2程序驗(yàn)證全面性生產(chǎn)質(zhì)量診斷程序根本原因減少生產(chǎn)標(biāo)準(zhǔn)化防誤34TotalProductiveMaintenanceisanequipmentmanagementstrategythatimprovesequipmentefficiency.全面生產(chǎn)性維護(hù)是一種設(shè)備管理策略以提高設(shè)備效率。Or,inotherwords...Treatingtheequipmentlikeitisyourown!或者，換句話說…….對(duì)待設(shè)備就象它是你自己的一樣！TPM全面生產(chǎn)性維護(hù)3TotalProductiveMaintenance35TPMKeyConceptTPM的重要概念Leftneglected...EquipmentBreaksDown如果不重視…設(shè)備很快就會(huì)壞TPM’sfocusistopreventproblemsbeforeequipmentbreaks.TPM的焦點(diǎn)是要在設(shè)備出故障以前防止問題出現(xiàn)。Inthepast,maintenancefocused

on

fixingequipmentafteritbroke.過去，維護(hù)工作總是集中在設(shè)備壞了以后對(duì)其進(jìn)行修理。4TPMKeyConceptTPM的重要概念Left36TotalProductiveMaintenance

isaNewWayofWorking

全面生產(chǎn)性維護(hù)是一種全新的工作方式TPMAttitude:TPM態(tài)度：“Weareallresponsibleforourequipment.”“我們所有人對(duì)我們的設(shè)備負(fù)責(zé)?！監(jiān)ldAttitude:過去的態(tài)度：“Ioperate,youfix.”“我操作，你修理?！薄癐fix,youdesign.”“我處理，你設(shè)計(jì)。”“Idesign,youoperate.”“我設(shè)計(jì)，你操作?！?TotalProductiveMaintenance37Afailureisjustthetipoftheiceberg!故障只是冰山的一個(gè)小尖！HiddenDefects隱藏的問題Failures故障Wear,play,slackness,leakage,dust,dirt,corrosion,deformation,adherenceofrawmaterials,surfacedamage,cracking,overheating,vibration,noise,andotherabnormalities.磨損、松馳、泄露、灰塵、污垢、腐蝕變形、原材料粘黏、表面磨損、裂縫、過熱、震動(dòng)、噪音及其它不正?，F(xiàn)象。TipoftheIceberg

冰山的頂端6AfailureisjusttheHiddenF38TypicalCausesofMachineBreakdown

典型的機(jī)械故障原因Failuretoaddoil.沒有加油Gritandchipsinrevolvingorslidingparts旋轉(zhuǎn)或滑動(dòng)零件中的砂礫和碎片Contaminationofsensors,contactsandConnectors傳感器、觸敏器、連接器污染Dirtanddustoncoolingfan冷卻風(fēng)扇上有灰塵和污垢ComponentFailure組件失靈Iwonderwhat’sgoingtofailnext?我在想下面還會(huì)出什么問題呢？7TypicalCausesofMachineBre39TPMTechniquesTPM技術(shù)NormaloperatingRange正常操作范圍Danger!危險(xiǎn)！SimplifyandDocumentTPMActivities.簡化并記錄TPM行動(dòng)Usevisualtechniquestoindicatewhat’sright/what’swrong.運(yùn)用直觀技術(shù)來演示什么是對(duì)的/什么是錯(cuò)的。PMCompleted?生產(chǎn)性維護(hù)完成了嗎？Pressuregage壓力計(jì)Sightglass視鏡Arrowsformotorrotationandfluidcirculation馬達(dá)旋轉(zhuǎn)和潤油指示箭頭markingsforsparepartsandfluids.備用零件和潤滑油記號(hào)MakingPMdevicesmoreaccessible.使生產(chǎn)性維護(hù)設(shè)備更容易獲得Filters,fittingsmademoreaccessible過濾器、各種裝置Transparentpanelstofacilitateinspection明了易讀的儀表盤便于檢查8TPMTechniquesTPM技術(shù)Normalop40TPMBenefitsTPM的益處Reducedmaintenancecosts減少維護(hù)費(fèi)用Breakdownmaintenanceis10timesmorecostlythanplannedmaintenance故障維修費(fèi)用是有計(jì)劃進(jìn)行維護(hù)費(fèi)用的10倍以上Enhancedsafety提高安全性Findexposedwires,openbelts,missingguards,loosehardware發(fā)現(xiàn)暴露在外的電線、松開的安全帶、缺少防護(hù)、松開的部件Reducedwaste減少浪費(fèi)Preventslossoflubricant,compressedair防止?jié)櫥?、壓縮空氣的浪費(fèi)Improvedquality提高品質(zhì)Equipmentmorecapableofholdingtolerance設(shè)備抗性增強(qiáng)Lessdowntime,longerlife縮短停工時(shí)間，壽命更長9TPMBenefitsTPM的益處Reducedma4112TPMQualifyingActivitiesACEElementAwarenessTrainingLockOut/TagOutawarenesstrainingavailableforallemployees(withannualrefresher)OperatorsofhighhazardequipmentinformedofmachinespecifichazardsAssessmentofmachinespecificsafeguarding(SP-008)issuesLockOut/TagOutEquipmentAvailableReviewOnlyActionItemsAssessallEquipmentA,B&CImplementwrittenLockOut/TagOutprocedureWalkaroundsafetycheckon100%ofA/BequipmentPMSchedulefor100%ofA/BequipmentCleaningon100%ofA/BequipmentTrackdowntimehistoryToptendowntimeequipmentidentified1012TPMQualifyingActivities4212項(xiàng)TPM合格行動(dòng)ACE內(nèi)容認(rèn)知培訓(xùn)鎖定/標(biāo)識(shí)認(rèn)知培訓(xùn)，針對(duì)所有員工（每年的復(fù)習(xí)進(jìn)修者）告知高危險(xiǎn)設(shè)備操作員有關(guān)機(jī)器的詳細(xì)危險(xiǎn)機(jī)器的特殊防護(hù)措施（SP-008）問題評(píng)估可用的鎖定/標(biāo)識(shí)設(shè)備僅用于檢查行動(dòng)內(nèi)容評(píng)估所有A,B&C類設(shè)備完成寫好的鎖定/標(biāo)識(shí)程序所有A/B類設(shè)備的安全巡查所有A/B類設(shè)備的生產(chǎn)性維護(hù)進(jìn)度表清潔所有A/B類設(shè)備追溯停工歷史確認(rèn)的十大停工設(shè)備1112項(xiàng)TPM合格行動(dòng)ACE內(nèi)容認(rèn)知培訓(xùn)僅用于檢查行43PURPOSEofLockout/Tagout鎖定/標(biāo)識(shí)的目的Topreventyouorsomeoneelsefrominadvertentlyturningapowersourceonandcausingapotentialinjuryorevendeath.以防你或它人意外開動(dòng)電源而造成可能的傷害甚至死亡Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查12PURPOSEofLockout/TagoutTo44LockoutDevice鎖定設(shè)備Alockorotherdevicethatutilizesapositivemeans,toholdanenergyisolatingdeviceinasafepositionandtherebypreventingtheenergizingofamachineorpieceofequipment.一把鎖或其它設(shè)備，用于使電源設(shè)備隔離裝置處于一安全的狀態(tài)，以防止機(jī)器或設(shè)備的一部分帶電。Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查13LockoutDevice鎖定設(shè)備Alockor45TagoutDefinition標(biāo)識(shí)的定義

Theprocessofsecurelyfasteningatagorprominentwarningsigntoindicatethatboththeenergyisolatingdeviceandtheequipmentbeingcontrolled,mustnot

beoperated.是將一標(biāo)簽或明顯的警告標(biāo)志緊附于設(shè)備上以表明不能對(duì)電源隔離設(shè)備及處于控制下的設(shè)備進(jìn)行操作。Thetagwillalsoincludethenameofthepersonwholockedouttheequipment.該標(biāo)簽應(yīng)有鎖定該裝置的人的名字。Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查14TagoutDefinition標(biāo)識(shí)的定義The46WARNING警告NEVERACCEPTLOCKOUTSKEYSFROMANYONE.決不要從它人處接受鎖定設(shè)備的鑰匙。THEASSOCIATERESPONSIBLEFORAPPLYINGTHELOCKORTAGISTHEONLYPERSONAUTHORIZEDTOREMOVETHELOCKORTAG.唯有經(jīng)授權(quán)負(fù)責(zé)運(yùn)用鎖或標(biāo)簽的人員可以拿掉該鎖或標(biāo)簽。Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查15WARNING警告NEVERACCEPTLOCKO47ACTIONITEM1:AssessAllEquipment

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備By“Equipment”wemeananymachinethatwasacapitalexpenseandhasadepreciativevalue.Oranymachinethatisimportanttoyourcell.所謂“設(shè)備”是指任何花費(fèi)了資金并會(huì)貶值的機(jī)器?；蛉魏螌?duì)你的部門重要的機(jī)器。WeCategorizeallEquipmentbasedonhowUniqueandCriticalitistoensurewefocusattentionontherightequipmentfirst.Payspecialattentiontobottleneckequipment.我們根據(jù)設(shè)備的獨(dú)特性和重要性對(duì)所有設(shè)備進(jìn)行分類，以確保我們的注意力優(yōu)先放在正確的設(shè)備上。對(duì)瓶頸設(shè)備給予特殊的關(guān)注。Equipment設(shè)備16ACTIONITEM1:AssessAllEq48CategoryA:

Criticalequipmentforwhichanalternatemachineisnotfeasible,because:A類：不能用其它設(shè)備替代的關(guān)鍵設(shè)備，因?yàn)椋篘oalternateexists,or無替代設(shè)備，或Thealternateisusuallyunavailableduetoutilization,or該替代設(shè)備通常正被使用而不能獲得，或Itwouldbetoocostly/timeconsumingtotransitiontothealternate太貴/需花太多時(shí)間進(jìn)行替換CategoryC:EquipmentforwhichitisrelativelyeasytofindareplacementoralternateC類：相對(duì)容易用其它設(shè)備替代的設(shè)備Includesmostoff-the-shelfequipment包括最常用的設(shè)備Typicallycost<$2,500費(fèi)用低于$2,500Standardspareparts(likedrivemotors)areavailableoff-the-shelf可獲得的常用標(biāo)準(zhǔn)備件（如驅(qū)動(dòng)馬達(dá)）CategoryB:

Allotherequipment/machinesB類：所有其它設(shè)備/機(jī)器ACTIONITEM1:AssessAllEquipment(cont.)

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）17CategoryA:Criticalequipme49Inadditiontomachinecategory,createatablelistingallmachinesandadditionalcategories,suchas:

除了機(jī)器分類，還應(yīng)作一表格列出所有機(jī)器和附加類別，如：Yearofmanufacture產(chǎn)品的生產(chǎn)年份Typeofmachine?Condition?(Good/Fair/Poor)機(jī)器類型？狀況？（好/一般/差）DoesOperatorPMprocessexists(Hasaservicecardbeencreated?)是否有操作員生產(chǎn)性維護(hù)程序（是否有服務(wù)卡？）DoesMaintenancePMprocessexist(Doesawrittenmaintenancetasklistexist?)是否有維護(hù)生產(chǎn)性維護(hù)程序（是否有記錄的維護(hù)任務(wù)表？）Hasthemachineundergoneinitialcleaning?機(jī)器是否經(jīng)過最初的清潔？HasmachinebeenassessedforsafeguardingperSP008?(EH&Sitems)機(jī)器是否經(jīng)過安全裝置SP008評(píng)估？（EH&S項(xiàng)）ACTIONITEM1:AssessAllEquipment(cont.)

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）18Inadditiontomachinecateg50PossibleCategories:可能的分類：Good:

Equipmentwhichretainsallofit’soriginalfunctions,accuracyandreliability.好：設(shè)備保持所有原來的功能，精確并可靠。Average:Equipmentwhichhaslostsomeofit’soriginalfunctionsoraccuracy.It’soutputnormallymeetstherequiredspecifications.一般：設(shè)備喪失了一些最初的功能或精確度。其產(chǎn)品符合要求的規(guī)范。Poor:

Equipmentwhichisnolongeraccurateorreliable.Inordertoproduceacceptableoutput,thisequipmentrequiresoperatorinterventionwellbeyondtheoriginallevel.差：設(shè)備不再精確或可靠。為了生產(chǎn)出可接受的產(chǎn)品，要求操作員對(duì)設(shè)備進(jìn)行超出原有水平的干涉。ACTIONITEM1:AssessAllEquipment(cont.)

行動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）19PossibleCategories:ACTIONI51ACTIONITEM2:WriteMachine-Specific

LockoutProcedures

LockoutproceduresmustbewrittenandimplementedforeachmachineGeneralproceduresareineffectforSullairProceduresneedtobewrittenjointlywithfacilitiesmaintenance20ACTIONITEM2:WriteMachine52行動(dòng)內(nèi)容2:將特殊鎖定程序?qū)懺跈C(jī)器上鎖定程序必須寫在每臺(tái)機(jī)器上并予以執(zhí)行一般程序適用于壽力公司程序必須與設(shè)備維護(hù)共同寫下來21行動(dòng)內(nèi)容2:將特殊鎖定程序?qū)懺跈C(jī)器上鎖定程序必須寫在53

ACTIONITEM3/4:

OperatorWalkaroundand PMScheduleon100%A/BOperatorPMdefinedfor100%ofCategoryAandBmachinesAbookorsheetexistswhichdefinesthedaily/weekly/monthlyOperatorPMtasksIncludesafetyequipmentoperation(guards,limitswitches,etc.)inOperatorPM.OperatorPMconductedfaithfully(1monthpriortoaudit)onallEquipmentforwhichitisdefined.Rev:BRevisionDate:3/25/98OperatorPreventiveMaintenanceServiceCardMachine:OkumaLC-30,4Axis,BT#3054DailyPMTasks1.

Checkrunningsight.2.

CheckandfillWaylube:Vactra2.3.

Checktrampoilandscrounger.Emptytrampoilifrequired.4.

Checkandfillcoolant:PML9333.WeeklyPMTasks:DoDaily

tasksand

thefollowing:1.

Checkandfillspindlelube:DTE24.2.

Checkandfillairlubricator:DTE24.(Shutoffanddrainairtofill)3.

Checkmotorfanfilter(Changeifnecessary):Cat.#030058.4.

Checkandfillhydraulictank:DTE24.5.

Checkrollfilter(Changeifneeded):Cat.#027793.MonthlyPMTasks:

Doall

tasksonthissheet.1.

Greasechuckfittings,1shot.2.

Grease1fitting,2shots,bothturrets.3.

Cleanairfilter.4.

Changeairfilter:Cat.#021183.22ACTIONITEM3/4:OperatorW54

行動(dòng)內(nèi)容3/4:

操作員巡查和 所有A/B類設(shè)備的PM進(jìn)度表操作員PM定義為所有A、B類機(jī)器應(yīng)有寫明了操作員每日/周/月的PM任務(wù)的書或表包括安全設(shè)備（防護(hù)裝置、限定電閘等）操作員嚴(yán)格地按要求對(duì)所有設(shè)備進(jìn)行生產(chǎn)性維護(hù)（在審查前一個(gè)月）Rev:BRevisionDate:3/25/98OperatorPreventiveMaintenanceServiceCardMachine:OkumaLC-30,4Axis,BT#3054DailyPMTasks1.

Checkrunningsight.2.

CheckandfillWaylube:Vactra2.3.

Checktrampoilandscrounger.Emptytrampoilifrequired.4.

Checkandfillcoolant:PML9333.WeeklyPMTasks:DoDaily

tasksand

thefollowing:1.

Checkandfillspindlelube:DTE24.2.

Checkandfillairlubricator:DTE24.(Shutoffanddrainairtofill)3.

Checkmotorfanfilter(Changeifnecessary):Cat.#030058.4.

Checkandfillhydraulictank:DTE24.5.

Checkrollfilter(Changeifneeded):Cat.#027793.MonthlyPMTasks:

Doall

tasksonthissheet.1.

Greasechuckfittings,1shot.2.

Grease1fitting,2shots,both