ANS 全員生產(chǎn)保全 簡(jiǎn)體字

TotalProductiveMaintenance

全員生產(chǎn)保全TotalProductiveMaintenance

全員生產(chǎn)保全

MeaningofTPM全員生產(chǎn)保全之意義AJapaneseKaizenStrategyfocusonimprovingtheefficiencyofmachinetogaintheoverallprofitofthecompany.

為日本的改善策略活動(dòng)之一種，著眼于改進(jìn)機(jī)器設(shè)備的效率，以提升公司整體的利益。TotalProductiveMaintenance

全員生產(chǎn)保全

FeaturesofTPMTPM之特徵

Emphasizeoverallcompanyefficiency

著重企業(yè)整體的效率化AchieveZeroDefect,ZeroAccident,ZeroShutdown追求零不良、零災(zāi)害、零故障Involvealldepartments,Production,R&D,Marketing包含所有部門，生產(chǎn)、開(kāi)發(fā)、營(yíng)業(yè)部門Allemployeesparticipation,fromCEOtooperator從總經(jīng)理到作業(yè)員均參與KaizenbySmallGroupActivities以小團(tuán)隊(duì)活動(dòng)來(lái)進(jìn)行改善TotalProductiveMaintenance

全員生產(chǎn)保全

BenefitsofimplementingTPMTPM之目的

Reduceshutdowntimetodeliverproductontime

減少停機(jī)，交期準(zhǔn)時(shí)StabilizeMachineCapabilitytoassurequalitylevel穩(wěn)定性能，確保質(zhì)量IncreaseOverallEquipmentEfficiencytoreducecost提升效率，降低成本Upgradeoperationskillstoguaranteesafety提升技能，保證安全

TotalProductiveMaintenance

全員生產(chǎn)保全

LevelofMaintenance保全的境界

BM:BreakdownMaintenance事后保全PM:PreventiveMaintenance預(yù)防保全CM:CorrectiveMaintenance改良保全MP:MaintenancePrevention保全預(yù)防TotalProductiveMaintenance

全員生產(chǎn)保全

6PillarsofTPMTPM六大支柱

User’sMaintenance自主保全PlannedMaintenance計(jì)劃保全CaseCorrection個(gè)別改善InitialManagement初期管理EasierManufacturing易制設(shè)計(jì)EducationTraining教育訓(xùn)練

TotalProductiveMaintenance全員生產(chǎn)保全

RelationshipbetweenPillarsandLevels

支柱與境界之關(guān)連

Breakdown

事后Maintenance保全User’sMaintenance

自主保全PlannedMaintenance

計(jì)劃保全CaseCorrection個(gè)別改善EducationTraining

教育訓(xùn)練InitialManagement初期管理EasierManufacturing

易制設(shè)計(jì)Preventive

預(yù)防Maintenance保全Corrective

改良Maintenance保全Maintenance保全Prevention

預(yù)防TotalProductiveMaintenance

全員生產(chǎn)保全

6MajorLossesofMachine設(shè)備六大損失

EquipmentBreakdown故障損失MinorStoppage瞬停損失Changeover/Adjustment換模損失Defects/Rework不良損失SpeedReduction退化損失WaitingOperation等待損失

TotalProductiveMaintenance全員生產(chǎn)保全

RelationshipamongLosses,PillarsandJob

Function(1/2)損失、支柱與職務(wù)之關(guān)連(1/2)

Losses損失Pillars支柱

EquipmentBreakdown故障損失User’sMaintenance

自主保全PlannedMaintenance計(jì)劃保全CaseCorrection個(gè)別改善EducationTraining教育訓(xùn)練InitialManagement初期管理EasierManufacturing易制設(shè)計(jì)MinorStoppage瞬停損失ChangeoverAdjustment換模損失DefectRework不良損失SpeedReduction

退化損失WaitingOperation等待損失

TotalProductiveMaintenance全員生產(chǎn)保全

RelationshipamongLosses,PillarsandJob

Function(2/2)損失、支柱與職務(wù)之關(guān)連(2/2)

Pillars支柱Job職務(wù)

User’sMaintenance自主保全Operator作業(yè)員Supervisor線長(zhǎng)MaintenanceTechnician保全員Consultant顧問(wèn)MaintenanceEngineer工程師DevelopEngineer開(kāi)發(fā)PlannedMaintenance計(jì)劃保全CaseCorrection個(gè)別改善EasierManufacturing易制設(shè)計(jì)InitialManagement初期管理EducationTraining教育訓(xùn)練TotalProductiveMaintenance

全員生產(chǎn)保全

MeasuresforEquipment設(shè)備績(jī)效衡量指標(biāo)

OverallEquipmentEfficiency設(shè)備總合效率(可動(dòng)率)Measureoftheavailable,performanceandqualityefficiencyofequipment

衡量設(shè)備的時(shí)間、性能及質(zhì)量之效率

MeanTimeBetweenFailures平均故障間隔時(shí)間

MeanFrequencyOfFailure平均故障次數(shù)Measureofthereliabilityof

equipment

衡量設(shè)備的可靠能力

MeanTimeToRepair平均修護(hù)時(shí)間Measureofthemaintainabilityofequipment

衡量設(shè)備的維修能力TotalProductiveMaintenance

全員生產(chǎn)保全

DefinitionofOEE(1/2)設(shè)備總合效率之定義OEE可動(dòng)率=EquipmentAvailableEfficiency

設(shè)備時(shí)間效率xPerformanceEfficiency性能效率xQualityEfficiency質(zhì)量效率EquipmentAvailableEfficiency設(shè)備時(shí)間效率:

Lossofbreakdown故障損失Lossofchangeover換模損失Lossofinspection檢查損失Lossofwaiting等待損失

TotalProductiveMaintenance

全員生產(chǎn)保全

DefinitionofOEE(2/2)設(shè)備總合效率之定義

PerformanceEfficiency性能效率:

Lossofminorstoppage瞬停損失Lossofdummyrunning空轉(zhuǎn)損失Lossofspeedreducing退化損失

QualityEfficiency質(zhì)量效率:

Lossofdefects不良損失Lossofrework重修損失Lossofretest重測(cè)損失

TotalProductiveMaintenance

全員生產(chǎn)保全

CalculationofOEE可動(dòng)率的算法(1/2)(A)TotalTimeaday每日時(shí)間=60min分x24Hrs小時(shí)=1440min分(B)PlannedShutdownTime計(jì)劃停機(jī)時(shí)間=480min分b1)BreakTime休息時(shí)間=60min分x2=120min分b2)PreventiveMaintenance預(yù)防保全時(shí)間=60min分x2=120min分b3)NoOrderWaitingTime無(wú)定單等待時(shí)間=60min分x4=240min分(C)ProductionScheduledTime生產(chǎn)計(jì)劃時(shí)間(=A-B)=960min分(D)UnscheduledDownTime意外停止時(shí)間=100min分d1)Breakdown故障=20min分d2)Changeover/Setup/Adjustment換模/安裝/調(diào)整=40min分d3)ToolsChange/Inspection刀具更換/檢查=30min分d4)WaitingOperator/Materials等待人員/材料=10min分

TotalProductiveMaintenance

全員生產(chǎn)保全

CalculationofOEE可動(dòng)率的算法(2/2)(E)AvailableOperationTime有效生產(chǎn)時(shí)間(=C-D)=860min分

Equipment

AvailableEfficiency設(shè)備時(shí)間效率(=E/C=860/960)=89.6%(G)TotalOutputQuantity全部生產(chǎn)數(shù)量(=1450pcs個(gè))IdealCycleTime理論周期時(shí)間(=0.5min分/pc個(gè))

EquipmentPerformance/Efficiency設(shè)備性能效率｛=(GxH)/E｝=84.3%TotalRejectedQuantity總不良數(shù)=200pcs個(gè)

EquipmentQualityEfficiency設(shè)備品質(zhì)效率｛=(G-J)/G｝=86.2%OEE可動(dòng)率=FxIxK=89.6%x84.3%x86.2%=65.1%

or或者=(G-J)xH/C=65.1%TotalProductiveMaintenance

全員生產(chǎn)保全

WhatisUser’sMaintenance何謂自主保全

Theuserof

equipmentisresponsibleforsomebasicmaintenanceactivitiesofequipment

由使用機(jī)器設(shè)備的操作者，負(fù)責(zé)從事一些機(jī)器設(shè)備的基本保全工作之意。TotalProductiveMaintenance

全員生產(chǎn)保全

ObjectivesofUser’sMaintenance自主保全之目的

Increasetheuser’scareonequipment.

提升操作者對(duì)設(shè)備的關(guān)心度

Increasetheuser’scapabilitytooperateequipment

提升操作者對(duì)設(shè)備的操作能力

Increasetheuser’scapabilityto

findouttheabnormalsituationofequipmentearlier.

提升操作者能早期發(fā)覺(jué)設(shè)備異常狀況之能力

ToincreasethereliabilityandOEEofequipment.

提升設(shè)備的可靠能力及提升設(shè)備的可動(dòng)率

TotalProductiveMaintenance全員生產(chǎn)保全

SevenStepsofUser’sMaintenance

自主保全展開(kāi)七步驟1)Initialcleaningandcheck初期清掃點(diǎn)檢2)Eliminationofsourcesofcontamination

排除困難發(fā)生源頭3)Establishstandardsofcleaningandlubrication

作成清掃及潤(rùn)滑基準(zhǔn)4)Implementgeneralinspectionandtraining

實(shí)施總點(diǎn)檢及技能教育5)Implementinspectionbyuser實(shí)施自主點(diǎn)檢6)Implementqualityassurance實(shí)施質(zhì)量保證7)Maintainstandardsandcontinueimprovement

自主維持管理及提升水平Purpose目的Learntheteamworkactivitiesandleadershipskills

學(xué)習(xí)團(tuán)隊(duì)活動(dòng)及領(lǐng)導(dǎo)技能Learntheconceptof“cleaningmeanscheck”學(xué)習(xí)“清掃即是點(diǎn)檢”之觀念Learnthesafetyoperationprocedure學(xué)習(xí)安全操作程序Exposetheabnormalconditionofequipmentandcorrection找出設(shè)備異常之處及復(fù)原

TotalProductiveMaintenance全員生產(chǎn)保全

Step1ofUser’sMaintenance(1/2)

自主保全第一步驟(1/2)Initialcleaningandcheck初期清掃點(diǎn)檢MainActivities主要活動(dòng)

Removeunneededparts設(shè)備不要之物移走Cleanequipment清掃設(shè)備Discoverabnormalcondition發(fā)覺(jué)異常之處*Listofdifficultcleaning清掃困難表*Listofunstablecondition不佳狀態(tài)表*Listofquery疑惑一覽表*Listofcontaminationsource污染源頭表Correcttheabnormalcondition復(fù)元異常之處*RedTagforabnormalcondition異常之處貼上膏藥單(紅單)

TotalProductiveMaintenance全員生產(chǎn)保全

Step1ofUser’sMaintenance(2/2)

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