TPM全面生產(chǎn)維護中英文演示文稿

TPM全面生產(chǎn)維護中英文版演示文稿目前一頁\總數(shù)一百頁\編于十七點TotalProductiveMaintenance(TPM)TPMTPMTeamOrganizationOverallEquipmentEffectivenessTPMPhasesRD011202目前二頁\總數(shù)一百頁\編于十七點精益6

過程改善流程分析控制改進定義選定題目列出客戶從顧客之聲中列出關建需求定出項目焦點和重要指標完成PDF測量繪制業(yè)務流程圖繪制價值流程圖制定數(shù)據(jù)收集計劃測量系統(tǒng)分析收集數(shù)據(jù)過程能力分析分析提出關鍵因子區(qū)分關鍵因子驗證關鍵因子評枯每個關鍵因子對結果的影響量化機會根本原因排序?qū)ふ腋驹蜥槍﹃P鍵因子改進關鍵因子確認發(fā)掘潛在的解決方法選擇方案優(yōu)化方案實行方案控制過程變革和控制制定控制計劃計算最終財務過程指標項目過渡給未來項目管理者項目鑒別轉化機會測量定義項目編號工具項目定義表凈現(xiàn)值分析內(nèi)部回報率分析折算現(xiàn)金流分析PIP管理過程RACIQuad表過程圖價值分析腦力風暴投票歸類法柏拉圖因果圖/魚骨圖FMEA查檢表運行圖控制圖量具R&RCp&Cpk供應鏈加速器分析多變動圖i盒狀圖交互作用圖回歸分析ANOVAC&E矩陣圖FMEA腦力風暴拉系統(tǒng)減少設置TPM流程圖標桿管理親和圖DOE假設檢驗力場分析圖樹狀圖甘特圖查檢表運行圖柱狀圖散布圖控制圖柏拉圖互動回顧愚巧法Revised1-12-023TotalProductiveMaintenance(TPM)目前三頁\總數(shù)一百頁\編于十七點LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-024TotalProductiveMaintenance(TPM)目前四頁\總數(shù)一百頁\編于十七點課程目的學習一種方法以便:將作業(yè)流程中的起作用的所有生產(chǎn)要素整合為一個單一綜合的衡量值（OEE）;消除導致設備故障的因素;使設備的養(yǎng)護清潔更易達成;用預測性保養(yǎng)作為一種檢測工具;實施維護審查5TotalProductiveMaintenance(TPM)目前五頁\總數(shù)一百頁\編于十七點LearningObjectivesLearnamethodto:IntegrateoperationalproductivityfactorsapplicableinprocessindustriesinasinglecomprehensivemeasurementEliminatefactorscontributingtoequipmentfailureImproveaccessibilityforcleaningandmaintainingequipmentUsepredictivemaintenanceasadiagnostictoolImplementmaintenanceaudits6TotalProductiveMaintenance(TPM)目前六頁\總數(shù)一百頁\編于十七點個人學習意義流程作業(yè)和保養(yǎng)最優(yōu)化一種替代傳統(tǒng)的在故障發(fā)生時檢測并修復的方法;一種源頭監(jiān)控和校正的先發(fā)系統(tǒng);一種基于對影響過程性能的主要因素其因果系統(tǒng)的理解工作策略;7TotalProductiveMaintenance(TPM)目前七頁\總數(shù)一百頁\編于十七點What’sinItforMe?OptimizedprocessoperationsandmaintenanceAmethodtoreplacethetraditionalapproachofdetectingandcorrectingfaultyconditionsastheyoccurAproactivesystemwhichmonitorsandcorrectscausesAnoperationsstrategybasedonunderstandingthecauseandeffectsystemaffectingthemajorcontributorstoprocessperformance8TotalProductiveMaintenance(TPM)目前八頁\總數(shù)一百頁\編于十七點全面生產(chǎn)維護(TPM)定義:一種用于監(jiān)控操作,設備保養(yǎng),消除計劃外停機,和提高作業(yè)與保養(yǎng)協(xié)調(diào)程度的常識性方法。9TotalProductiveMaintenance(TPM)目前九頁\總數(shù)一百頁\編于十七點TotalProductiveMaintenance(TPM)TPMDefinitionAcommonsenseapproachtomonitoroperations,maintainequipment,eliminateunscheduleddowntime,andimprovethelevelofcooperationbetweenOperationsandMaintenance.10TotalProductiveMaintenance(TPM)目前十頁\總數(shù)一百頁\編于十七點TPM通過實施預防實現(xiàn)設備零故障和零缺陷;預防工作將立足于以下方面:維持正常的生產(chǎn)條件及早發(fā)現(xiàn)異?？焖俜磻?1TotalProductiveMaintenance(TPM)目前十一頁\總數(shù)一百頁\編于十七點TPMAchievezeroequipmentbreakdownsandzerodefectsthroughpreventionEstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponse12TotalProductiveMaintenance(TPM)目前十二頁\總數(shù)一百頁\編于十七點傳統(tǒng)的反應式維護維修部門–“我們只管修理”執(zhí)行所有的維修作業(yè)往往是一旦設備發(fā)生故障充當救火員的角色;負責定購和保管所有的工具,備件等物資;實施定期檢修生產(chǎn)部門–”我們只管使用“通常不作任何維護活動一旦設備出現(xiàn)故障就與維修部門聯(lián)系維修作業(yè)中只能停工;一直用到壞了為止13TotalProductiveMaintenance(TPM)目前十三頁\總數(shù)一百頁\編于十七點TraditionalApproach

“Re-ActiveMaintenance”Maintenance–

“WEFIX”PerformallmaintenanceactivitiesPerform“FireFighting”maintenancewhenamachinebreakdownoccursOrderandadministeralltooling,supplies,etc.PerformPreventiveMaintenanceManufacturing–

“WEOPERATE”GenerallydoesnotperformanymaintenanceactivitiesContactsmaintenancewhenamachinebreakdownoccursInactiveduringmaintenanceactivities“Runit'tillitbreaks”14TotalProductiveMaintenance(TPM)目前十四頁\總數(shù)一百頁\編于十七點主要概念 定期保養(yǎng)是一種基于時間長短或使用狀況對設備進行檢修的方法.在指定時間或在使用空檔間對設備實施檢修作業(yè)以防止設備發(fā)生故障.定期保養(yǎng)計劃 預測性保養(yǎng)是一種基于設備狀態(tài)的維護方法.根據(jù)可視信號或檢測技術的情況來實施保養(yǎng)以防止設備發(fā)生故障.振動分析激光探測超聲波檢測發(fā)電機測試熱感應油況分析預測性保養(yǎng)定期保養(yǎng)15TotalProductiveMaintenance(TPM)目前十五頁\總數(shù)一百頁\編于十七點KeyDefinitions

PreventiveMaintenanceisatimeorusagebasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedondefinedtimeand/orusageintervalstopreventequipmentbreakdownsfromoccurring.PMSchedules

PredictiveMaintenanceisasituationbasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedonvisiblesignalsordiagnostictechniquestopreventequipmentbreakdownsfromoccurring.VibrationAnalysisLaserMeasuringUltrasoundGeneratorTestingThermographyOilAnalysisPredictiveMaintenancePreventiveMaintenance16TotalProductiveMaintenance(TPM)目前十六頁\總數(shù)一百頁\編于十七點現(xiàn)狀分析和團隊組織評估當前的操作條件:機器利用率,生產(chǎn)率等;維修費用(配件和人工)對實現(xiàn)TPM的各項工作進行優(yōu)先次序評估潛在TPM倡導者及團隊成員的實力挑選TPM倡導者及團隊成員建立初始的實施專門小組確定團隊目標17TotalProductiveMaintenance(TPM)目前十七頁\總數(shù)一百頁\編于十七點PresentStateAnalysis

andTeamOrganizationAssessCurrentOperatingConditionsMachineutilization,productivity,etc.Maintenancerepaircosts(partsandlabor)PrioritizeorderofTPMeffortsAssesscapabilitiesofpotentialTPMChampionsandTeamMembersSelectTPMChampionandTeamMembersEstablishinitialkick-offworkshopEstablishteamgoal18TotalProductiveMaintenance(TPM)目前十八頁\總數(shù)一百頁\編于十七點典型的設備評價指標利用率:設備實際運轉時間與總的可利用時間的比率;=實際運行時間/可運行時間效率:實際產(chǎn)量與標準產(chǎn)量的比率=(實際產(chǎn)量/小時)/(標準產(chǎn)量/小時)產(chǎn)出:用一特定時間段的產(chǎn)量來衡量=磅/小時,件數(shù)/小時19TotalProductiveMaintenance(TPM)目前十九頁\總數(shù)一百頁\編于十七點TypicalOperationalProcessMeasurementsUtilization:Theratioofequipmentactualoperatingtimetothetotalavailableoperatingtime=ActualOperatingTime/AvailableTimeEfficiency:Theratioofactualproductproducedtoastandard=(ActualParts/Hour)/(StandardPart/Hour)Output:Measureofoutputoveraspecifiedtimeperiod=lbs/hr,pieces/hr20TotalProductiveMaintenance(TPM)目前二十頁\總數(shù)一百頁\編于十七點設備綜合利用率OEE設備綜合利用率（OEE）是衡量一臺設備按計劃速度生產(chǎn)出合格產(chǎn)品的時間占全部時間的百分比.21TotalProductiveMaintenance(TPM)目前二十一頁\總數(shù)一百頁\編于十七點OverallEquipmentEffectivenessOverallEquipmentEffectiveness(OEE)isthemeasureofthepercentoftimeapieceofequipmentisproducingqualityproductatthedesignedrate.22TotalProductiveMaintenance(TPM)目前二十二頁\總數(shù)一百頁\編于十七點OEE分解:六大浪費故障及輕微故障使設備中斷運行的時間超過10分鐘的故障或者中斷時間少于10分鐘的輕微故障.設置時間浪費任何與設備調(diào)整,裝配,清潔相關的作業(yè).機器空轉浪費設備在運轉卻沒有用來生產(chǎn)產(chǎn)品所耗用的時間.

速度浪費由于設備或產(chǎn)品的異常造成設備以低于標準速度或所設定的速度運轉.品質(zhì)原因浪費為確保設備產(chǎn)出品的品質(zhì)而采取相關的作業(yè)(過程中檢查).

返工浪費用于返修產(chǎn)品或生產(chǎn)出報廢產(chǎn)品所耗用的時間.可用水平(AL)運行水平(OL)質(zhì)量水平(QL)23TotalProductiveMaintenance(TPM)目前二十三頁\總數(shù)一百頁\編于十七點OEEBreakdown:

TheSixBigLossesBreakdownsand

MinorStoppagesMalfunctionscausingequipmenttostopprocessinggreaterthan10minutes(breakdowns)orlessthan10minutes(minorstoppages)SetupAnyactivityrelatedtoequipmentchangeover,setup,orcleaning.IdlingTimeequipmentisrunningbutnotproducingproduct.

SpeedLossesEquipmentoperatingatlessthanstandardordesignspeedduetoequipment/productabnormalityQualityFactorsActivitiesrelatedtoensuringthequalityoftheproductproducedontheequipment(in-processchecks).

ReworkLossesThetimetakentore-processproductortimetaketoproduceun-usableproduct.AvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)24TotalProductiveMaintenance(TPM)目前二十四頁\總數(shù)一百頁\編于十七點六大浪費的識別練習25TotalProductiveMaintenance(TPM)目前二十五頁\總數(shù)一百頁\編于十七點SixBigLossesIdentificationExercise26TotalProductiveMaintenance(TPM)目前二十六頁\總數(shù)一百頁\編于十七點OEE的計算原理承載時間(LT)設備運轉總的可利用時間=40hrs可用水平(AL)運行水平(OL)質(zhì)量水平(QL)OEE73%x91%x80%

26.3-3.1-2.1=80%26.3

28.9-1.5-1.1=91%28.9質(zhì)量原因機器故障及輕微故障,行政事務/非作業(yè)時間機器設置與調(diào)整速度損失機器空轉返工及報廢

40-3.1-3.8-4.2=73%40OEE=53%ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrs27TotalProductiveMaintenance(TPM)目前二十七頁\總數(shù)一百頁\編于十七點CalculatingOEEElementsLoadingTime(LT)TotalHoursAvailableforEquipmentOperation=40hrsAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE73%x91%x80%

26.3-3.1-2.1=80%26.3

28.9-1.5-1.1=91%28.9QualityFactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrap

40-3.1-3.8-4.2=73%40OEE=53%ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrs28TotalProductiveMaintenance(TPM)目前二十八頁\總數(shù)一百頁\編于十七點世界級的OEE性能水平承載時間(LT)同步計劃運轉時間及生產(chǎn)性防護時間可用水平(AL)運行水平(OL)質(zhì)量水平(QL)OEE90%x95%x99%質(zhì)量原因機器故障及輕微故障,行政事務/非作業(yè)時間機器設置與調(diào)整速度損失機器空轉返工及報廢OEE=85%是世界級的性能水平AL始終保持在90%以上OL維持在95%以上QL不低于99%29TotalProductiveMaintenance(TPM)目前二十九頁\總數(shù)一百頁\編于十七點WorldClassOEEPerformanceLoadingTime(LT)OperationTimeandPMTimeisscheduledsynchronizingthetwoAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE90%x95%x99%QualityFactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrapOEE=85%isWorldClassPerformanceTheALisconsistentlykeptatorabove90%TheOLismaintainedatorabove95%TheQLisatorabove99%30TotalProductiveMaintenance(TPM)目前三十頁\總數(shù)一百頁\編于十七點使設備恢復到可靠狀態(tài)消除故障開發(fā)PM維護保養(yǎng)資料庫消除缺陷階段I階段II階段III階段IVTPM階段31TotalProductiveMaintenance(TPM)目前三十一頁\總數(shù)一百頁\編于十七點ReturnEquipmenttoReliableConditionEliminateBreakdownsDevelopPMInformationDatabaseEliminateDefectsPHASEIPHASEIIPHASEIIIPHASEIVTPMPhases32TotalProductiveMaintenance(TPM)目前三十二頁\總數(shù)一百頁\編于十七點六大團隊活動1. 通過小規(guī)模的小組活動來提高機器的正常運行時間,消除造成停工的主要根源:機器的啟動損失 機器的故障損失待料損失和生產(chǎn)安排不當帶來的停機損失2. 使操作員熟練地參與如潤滑,清潔,故障檢驗等基本的保養(yǎng)維護. 33TotalProductiveMaintenance(TPM)目前三十三頁\總數(shù)一百頁\編于十七點SixTeamActivities1. Usesmallgroupactivitiestoimprovemachineuptimebyeliminatingthemajorsourcesofdowntime.StartupLosses BreakdownLossesMaterialandSchedulingLosses2. Involvethemachineoperatorsaswellasskilledtradesinbasicpreventativemaintenancesuchaslubrication,cleaning,andinspectionfordefects. 34TotalProductiveMaintenance(TPM)目前三十四頁\總數(shù)一百頁\編于十七點六大團隊活動(續(xù)上頁)3. 使用諸如振動分析類的預測工具擯棄過去那種反應式的維護模式4. 增強對設備的認知和了解以提高生產(chǎn)效能,減少停工時間;5. 使供應管理和生產(chǎn)調(diào)度協(xié)同工作以確保持續(xù)穩(wěn)定的原材料供應,避免停機待料;6. 規(guī)劃人員配備以確保瓶頸設備處的滿員運作35TotalProductiveMaintenance(TPM)目前三十五頁\總數(shù)一百頁\編于十七點SixTeamActivities(Cont.)3. Utilizepredictivetoolssuchasvibrationanalysistomovepastreactivetypemaintenance4. Increaseawarenessandknowledgeofequipmenttoimproveproductivityandreducedowntime5. WorkwithSupplyManagementandProductionControltoinsureaconstantflowofrawmaterialisavailabletoprecludeidling.6. Developmanningschedulesthatinsurethatbottleneckmachinesarefullystaffed36TotalProductiveMaintenance(TPM)目前三十六頁\總數(shù)一百頁\編于十七點TPM的益處提升操作員的參與感使設備恢復至更高的性能水平發(fā)現(xiàn)并消除早期的設備隱患減少總的制造成本減少浪費在保養(yǎng)設備方面樹立榮譽感促進維護和生產(chǎn)部門之間的相互尊重與合作37TotalProductiveMaintenance(TPM)目前三十七頁\總數(shù)一百頁\編于十七點BenefitsofTPMPromotesoperatorinvolvementRestoresequipmenttoahigherperformancelevelUncoverandeliminateprematureequipmentfailuresReducetotalmanufacturingcostsReduceswasteBuildsasenseofprideinmaintainingtheequipmentPromotescooperationandrespectbetweenmaintenanceandproduction38TotalProductiveMaintenance(TPM)目前三十八頁\總數(shù)一百頁\編于十七點職責范圍精益6Sigma團隊倡導者/發(fā)起人TPM團隊操作員現(xiàn)場主管維護人員39TotalProductiveMaintenance(TPM)目前三十九頁\總數(shù)一百頁\編于十七點AreasofResponsibilityLeanSixSigmaTeamChampion/SponsorTPMTeamOperatorSupervisorMaintenance40TotalProductiveMaintenance(TPM)目前四十頁\總數(shù)一百頁\編于十七點精益6Sigma團隊的任務確定一個TPM項目的需求收集有關維護成本,延遲(時延或操作延遲,設備利用率以及質(zhì)量問題的歷史數(shù)據(jù)與操作員進行深入溝通以了解他們的期望41TotalProductiveMaintenance(TPM)目前四十一頁\總數(shù)一百頁\編于十七點LeanSixSigmaTeamRoleDeterminetheneedforaTPMProjectGatherhistoryofmaintenancecost,delay,machineavailability,andqualityproblemsInterviewOperatorstogettheirprospective42TotalProductiveMaintenance(TPM)目前四十二頁\總數(shù)一百頁\編于十七點現(xiàn)場活動組成TPM團隊負責設備維護的人員操作員一線管理人員準備必要的裝備幫助TPM團隊診斷異常協(xié)助跨功能培訓收集整理故障標牌的拷貝并生成工作明細表提供人力資源方面的支持精益6Sigma團隊的任務43TotalProductiveMaintenance(TPM)目前四十三頁\總數(shù)一百頁\編于十七點LeanSixSigmaTeamRoleOnflooractivitiesAssembletheTPMTeamMaintenancepersonnelOperatorsFirstlinesupervisionProvidenecessaryequipmentHelpteamdiagnoseabnormalitiesAssistskilledtradesCollectcopiesofdefecttagsandgenerateaworklistProvidepeopleresources44TotalProductiveMaintenance(TPM)目前四十四頁\總數(shù)一百頁\編于十七點倡導者/發(fā)起人的角色一旦完成現(xiàn)場工作,接下來將:形成工作任務并跟蹤其完成情況協(xié)助建立和引入正確的定期維護明細表協(xié)助維持改善結果評估設備綜合利用率OEE展示TPM的改善的成就45TotalProductiveMaintenance(TPM)目前四十五頁\總數(shù)一百頁\編于十七點Champion/SponsorRoleUponCompletionofOnFloorEventGenerateandtrackcompletionofworkordersAssistincreationandpostingofaccuratePeriodicMaintenanceListAssistinsustainingthegainsEvaluateOverallEquipmentEffectivenessDisplayTPMimprovements46TotalProductiveMaintenance(TPM)目前四十六頁\總數(shù)一百頁\編于十七點現(xiàn)場主管的角色指導并推廣TPM概念監(jiān)控現(xiàn)場的設備管理,保養(yǎng)及機器清潔工作的進行激發(fā)操作員的主人翁意識對操作員授權為TPM活動提供時間方面的準備促進生產(chǎn)與維護雙方的合作47TotalProductiveMaintenance(TPM)目前四十七頁\總數(shù)一百頁\編于十七點Supervisor’sRoleCoachandpromoteTPMConceptsMonitorongoinghousekeepingandmachinecleanlinessPromoteOperatorownershipEmpowerOperatorsProvidetimeforTPMactivitiesPromotecooperationbetweenProductionandMaintenance48TotalProductiveMaintenance(TPM)目前四十八頁\總數(shù)一百頁\編于十七點維護人員的角色

“專業(yè)的管理者”有計劃的實施所有的定期保養(yǎng)并根據(jù)需要采取維修措施;使用振動分析,磨損度分析,熱感應等預測工具;建立維護設備的保養(yǎng)記錄與操作員協(xié)同工作并提供技術支持執(zhí)行設備大修,綜合調(diào)試負責執(zhí)行一些特殊技能的任務,風險安全性高的作業(yè)促進TPM49TotalProductiveMaintenance(TPM)目前四十九頁\總數(shù)一百頁\編于十七點MaintenanceRole

“TheSpecializedCaretakers”PerformallplannedpreventativemaintenanceandtakecorrectiveactionasneededUsepredictivetoolssuchasvibrationanalysis,wearparticleanalysis,andthermographyDocumentequipmentmaintenancehistoryCooperatewithOperatorsandprovidetechnicalassistancePerformequipmentoverhaul,complexadjustmentsProvidespecialskilltasks,highsafetyrisktasksPromoteTPM50TotalProductiveMaintenance(TPM)目前五十頁\總數(shù)一百頁\編于十七點操作員角色

“一線管理者”清潔和缺陷檢查執(zhí)行基本的潤滑,多點檢測的工作按照核準清單的項目進行定期保養(yǎng)按計劃執(zhí)行日常清潔和整理識別剛剛發(fā)生的設備異常根據(jù)需要協(xié)助維護人員進行維修執(zhí)行基本的調(diào)試工作改善提案促進TPM51TotalProductiveMaintenance(TPM)目前五十一頁\總數(shù)一百頁\編于十七點Operator’sRole

“TheFirstLineCaretaker”CleanandinspectfordefectsPerformbasiclubrication,multi-pointinspectionPerformPeriodicMaintenanceperapprovedListPerformroutinecleaningandhousekeepingasscheduledIdentifyequipmentdefectsastheyariseAssistMaintenancewithrepairsuponrequestPerformbasicadjustmentsSuggestimprovementsPromoteTPM52TotalProductiveMaintenance(TPM)目前五十二頁\總數(shù)一百頁\編于十七點全面生產(chǎn)維護的七大步驟1.完成初始的機器清潔和檢查2.識別機器的缺陷和泄漏并加以標示3.建立操作員及維護人員的定期檢測的PM計劃4. 指導操作員使用正確的保養(yǎng)方法5. 指導維護人員使用正確的保養(yǎng)方法6. 貫徹現(xiàn)場5S管理和組織活動7. 監(jiān)控OEE并鼓勵大家合作53TotalProductiveMaintenance(TPM)目前五十三頁\總數(shù)一百頁\編于十七點The7Stepsof

TotalProductiveMaintenance1. Performinitialmachinecleaningandinspection2. Identifyandtagmachinedefectsandleaks3.DevelopOperatorandMaintenancePM’s4. InstructOperatorsinproperPMtechniques5. InstructMaintenanceStaffinproperPMtechniques6. Implement5SHousekeepingandOrganization7. MonitorOEEandencouragecooperation54TotalProductiveMaintenance(TPM)目前五十四頁\總數(shù)一百頁\編于十七點TPM安全常識遵守/使用停工現(xiàn)場標牌警示程序正確的起重方法用電安全操作規(guī)范勞保裝備手套工作鞋護目鏡防塵口罩耳塞55TotalProductiveMaintenance(TPM)目前五十五頁\總數(shù)一百頁\編于十七點TPMSafetyHabitsFollow/UseLockoutTagoutProcedureProperLiftingTechniquesElectricalSafetyGuidelinesPersonalProtectiveEquipmentGlovesSafetyShoesGogglesRespiratorsHearingProtection56TotalProductiveMaintenance(TPM)目前五十六頁\總數(shù)一百頁\編于十七點TPM步驟1初始的機器清潔和檢查目的:識別需修理處并標示缺陷執(zhí)行:徹底清潔機器團隊所有成員參與并將所有需要維修的項目標示并記錄57TotalProductiveMaintenance(TPM)目前五十七頁\總數(shù)一百頁\編于十七點TPMStep1InitialMachineInspectionPurpose:ToIdentifyneededrepairsandtagdefectsExecution:Cleanmachinethoroughly–donebyallteammembersTagandrecordallrepairsneededinaprojectnotebook58TotalProductiveMaintenance(TPM)目前五十八頁\總數(shù)一百頁\編于十七點TPM步驟1

“現(xiàn)場活動”徹底的清潔工作包括:清除所有的碎屑及其他殘余物徹底地去除油污調(diào)節(jié)壓縮空氣更換過濾器,潤滑劑等潤滑移動部件及接頭處清理不必要的使用工具,五金器具及備件等“你的雙手肯定會臟兮兮的!”59TotalProductiveMaintenance(TPM)目前五十九頁\總數(shù)一百頁\編于十七點TPMStep1

“OnFloorActivities”AThoroughCleaningIncludes:RemovingallchipsandotherdebrisThoroughDegreasingCompressedairforcontrolsChangingfilters,lubricants,etc.LubricatingmovingpartsandjointsRemovingunnecessarytooling,hardware,supplies,etc.“Youhavetogetyourhandsdirty!”60TotalProductiveMaintenance(TPM)目前六十頁\總數(shù)一百頁\編于十七點TPM步驟1

“現(xiàn)場活動”維修項標示色碼

標簽上須標示的信息:機器的資產(chǎn)編號機器位置及故障位置投入使用的日期及使用人機油泄漏—橙色冷卻液泄漏—綠色空氣泄漏–黃色機器故障–粉紅色電氣問題--藍色61TotalProductiveMaintenance(TPM)目前六十一頁\總數(shù)一百頁\編于十七點TPMStep1

“OnFloorActivities”RepairTagColorCodes

InformationNeededonTagsAssetnumberofmachineLocationandrelativepositionofdefectonmachineNameoforiginatoranddateOilLeaks-OrangeCoolantLeaks-GreenAirLeaks-YellowMachineDefects-PinkElectricalProblems-Blue62TotalProductiveMaintenance(TPM)目前六十二頁\總數(shù)一百頁\編于十七點關注TPM清潔效果

降低停機時間>70%之前–砂粒及碎屑很嚴重無法調(diào)試運行速度降低故障接連發(fā)生之后–跨功能工作的成果更換缺損的零部件調(diào)試校正恢復至設計速度且保持品質(zhì)63TotalProductiveMaintenance(TPM)目前六十三頁\總數(shù)一百頁\編于十七點FocusedTPMCleaningEffort

ReducedDowntimeby>70%Before–SevereGritandChipsOutofadjustmentsRunningatreducedspeedsConstantbreakdownsAfter–Cross-functionalEffortReplacedbrokenandmissingpartsCorrectedtheadjustmentReturnedtodesignedspeedwithoutincurringscrap64TotalProductiveMaintenance(TPM)目前六十四頁\總數(shù)一百頁\編于十七點TPM步驟2修復機器的缺漏目的:修復在步驟1中找到的缺漏項目注意事項:倡導者/發(fā)起人需確保標示出的問題得到修復實際的修復工作不必一定由團隊成員來做;生產(chǎn)主管須確保機器能夠使用65TotalProductiveMaintenance(TPM)目前六十五頁\總數(shù)一百頁\編于十七點TPMStep2RepairmachinedefectsandleaksPurpose:TorepairitemsfoundinStep1Considerations:Champion/SponsorinsurestaggedproblemsarerepairedActualrepairsdonothavetobedonebyteammembersProductionSupervisorhastomakemachineavailable66TotalProductiveMaintenance(TPM)目前六十六頁\總數(shù)一百頁\編于十七點TPM步驟2消除故障因素固定并擰緊所有的扣件,接頭,螺釘及螺母替換任何缺損的部件替換任何損壞,磨損及規(guī)格不符的零部件解決所有的滲漏,溢出,噴濺,噪雜等問題提高如下環(huán)節(jié)的可操作性:清潔潤滑調(diào)試檢查/測試67TotalProductiveMaintenance(TPM)目前六十七頁\總數(shù)一百頁\編于十七點TPMStep2Eliminatefactorscontributingtofailure:Secureandtightenallfasteners,fittings,boltsandscrewsReplaceanymissingpartsReplaceanydamaged,wornorwrongsizepartsResolveallcausesofleaks,spillage,sprayandsplatterImproveaccessibilityinordertoaccomplish:Cleaning LubricatingAdjustingChecking/inspecting68TotalProductiveMaintenance(TPM)目前六十八頁\總數(shù)一百頁\編于十七點TPM步驟3建立操作員和維護人員合作的PM計劃確保發(fā)出完善的定期檢測的查檢表目的:注意事項:由TPM項目小組建立PM計劃誰來執(zhí)行任務任務執(zhí)行的頻率(例如每天,每周等)69TotalProductiveMaintenance(TPM)目前六十九頁\總數(shù)一百頁\編于十七點TPMStep3DevelopOperatorPM’sandMaintenancePM’sPurpose:ToinsureadequatepreventativemaintenancechecklistsarepostedConsiderations:TPMProjectTeamtodevelopPM’sWhoistoperformtasksFrequencyoftasks(i.e.,daily,weekly,etc.)70TotalProductiveMaintenance(TPM)目前七十頁\總數(shù)一百頁\編于十七點TPM步驟4由操作員執(zhí)行的PM作業(yè)目的:盡早發(fā)現(xiàn)問題,準備周期保養(yǎng),遵循5S規(guī)程注意事項:操作員負責按照管理文件執(zhí)行PM工作;生產(chǎn)主管須確保PM工作的有效實施71TotalProductiveMaintenance(TPM)目前七十一頁\總數(shù)一百頁\編于十七點TPMStep4PMactivityperformedbytheOperatorPurpose:Todetectearlyproblems,providetheserviceinterval,andinsure5SprocedureisfollowedConsiderations:OperatorisresponsibletoperformPM’sasdocumentedProductionSupervisortoinsurePM’sareeffective72TotalProductiveMaintenance(TPM)目前七十二頁\總數(shù)一百頁\編于十七點TPMTPM使操作員更加獨立地自我管理和控制;操作員時時關注小問題的發(fā)生就有可能: 迅速地發(fā)現(xiàn)潛在的問題修正現(xiàn)有問題確定狀態(tài)正常良好地維持設備整體狀況73TotalProductiveMaintenance(TPM)目前七十三頁\總數(shù)一百頁\編于十七點TPMTPMmakestheoperatormoreindependentTheoperatorseesthesmallproblemsnowwiththepossibilityof: QuicklynotingpotentialproblemsCorrectingthecurrentsituationRecognizingnormalconditionsMaintainingthemachineingoodoverallcondition74TotalProductiveMaintenance(TPM)目前七十四頁\總數(shù)一百頁\編于十七點自主維護管理指的是操作員參與自己所操作的設備的維護作業(yè)怎樣使操作員更加自主,實現(xiàn)自我管理:利用文件管理明確維護/生產(chǎn)作業(yè)的規(guī)定明確操作員如何進行日常檢測進行基本的操作,維護及故障檢測的培訓使日常作業(yè)直觀,一目了然明確識別須監(jiān)督管理的項目75TotalProductiveMaintenance(TPM)目前七十五頁\總數(shù)一百頁\編于十七點AutonomousMaintenanceReferstoactivitiesinvolvingoperatorsinthemaintenanceoftheirownequipmentHowtomaketheoperatormoreindependent:MakedocumentationavailableDefinemaintenance/manufacturingactivitiesShowoperatorhowtoperformdailychecksTraininbasicoperation,maintenance,anddefectdetectionMakedailyactivitiesvisibleClearlyidentifyitemstosupervise76TotalProductiveMaintenance(TPM)目前七十六頁\總數(shù)一百頁\編于十七點落實自主維護管理確定過程實施中的關鍵機器及設備執(zhí)行初步清潔工作清除臟污及污染源建立清潔和潤滑標準就設備的保養(yǎng)需求對操作員進行培訓貫徹實施一個綜合性的維護系統(tǒng)對保養(yǎng)效果進行定期審查77TotalProductiveMaintenance(TPM)目前七十七頁\總數(shù)一百頁\編于十七點AutonomousMaintenanceImplementationIdentifyprocesscriticalmachineryandequipmentPerforminitialcleaningResolvesourcesofdirtandcontaminationCreatecleaningandlubricationstandardsTrainoperatorsonequipmentmaintenancerequirementsImplementacomprehensivemaintenancesystemEstablishperiodicauditsofmaintenanceeffectiveness78TotalProductiveMaintenance(TPM)目前七十八頁\總數(shù)一百頁\編于十七點為什么清潔?不恰當?shù)那鍧嵥鶐淼呢撁嬗绊?故障產(chǎn)品缺陷加快設備磨損產(chǎn)量降低設備磨損正常磨損:盡管正確操作仍然會發(fā)生加快磨損:由于誤操作及疏忽于保養(yǎng)導致加快磨損79TotalProductiveMaintenance(TPM)目前七十九頁\總數(shù)一百頁\編于十七點WhyClean?AdverseeffectsofinadequatecleaningFailureProductdefectsAccelerateddeteriorationThroughputlossEquipmentdeteriorationNormaldeterioration:occursdespitecorrectuseAccelerateddeterioration:quickerdeteriorationoccurringduetomisuseinoperationandneglectofmaintenance80TotalProductiveMaintenance(TPM)目前八十頁\總數(shù)一百頁\編于十七點清潔可作為磨損檢查清潔可減緩磨損速度接觸設備可發(fā)現(xiàn)異常情況采取保養(yǎng)措施可延長使用壽命,避除故障81TotalProductiveMaintenance(TPM)目前八十一頁\總數(shù)一百頁\編于十七點CleaningasDetectionofDeteriorationCleaningreducesaccelerateddeteriorationPhysicalcontactwithequipmentexposesabnormaloperationconditionsPreventiveactiontakenextendsusefullifeandavoidsbreakdowns82TotalProductiveMaintenance(TPM)目前八十二頁\總數(shù)一百頁\編于十七點常見的設備缺陷斷線軟管磨破漏油漏氣散熱劑泄漏托架損壞電線裸露多余及廢棄的器具防護裝置損壞或不見83TotalProductiveMaintenance(TPM)目前八十三頁\總數(shù)一百頁\編于十七點TypicalDefectsFoundBrokenflexWornhosesOilleaksAirLeaksCoolantleaksBrokenBracketsFrayedwiresUnnecessaryandobsoletetoolingDamagedormissingguards84TotalProductiveMaintenance(TPM)目前八十四頁\總數(shù)一百頁\編于十七點設備故障專家估計與移動裝置相關的機器故障有60%是由于缺乏或不適當?shù)臐櫥瑢е碌?建立設備故障資料庫收集并管理故障資料分析故障趨勢及形式定期展開和發(fā)布總結報告包括用于定期回顧之用的會議議程報告85TotalProductiveMaintenance(TPM)目前八十五頁\總數(shù)一百頁\編于十七點EquipmentFailuresExpertsestimatethat60%ofmachinebreakdownsassociatedwithmovingpartsareduetolackoforimproperlubricationpractices.EstablishanequipmentfailuredatabaseGatherandmanagefailureinformationAnalyzefortrendsandpatternsDevelopandissueperiodicsummaryreportsIncludereportsasameetingagendaforregularreview86TotalProductiveMaintenance(TPM)目前八十六頁\總數(shù)一百頁\編于十七點TPM步驟4(續(xù)）目視管理張貼設備潤滑工作示意圖標示油位玻璃管的上下線所有的氣管,水管,油管及冷卻劑管區(qū)分標示張貼OEE的圖表分析公布本年度截至目前為止的保養(yǎng)成本公布5S審查的得分情況87TotalProductiveMaintenance(TPM)目前八十七頁\總數(shù)一百頁\編于十七點TPMStep4（Con.)VisualsControlsLubricationplacardsinplaceUpperandlowersightglassesinplaceAllair,water,gas,andcoolantlinesarelabeledOEEpostedYTDMaintenancecostsposted5SAuditScoresposted88TotalProductiveMaintenance(TPM)目前八十八頁\總數(shù)一百頁\編于十七點TPM步驟5由維護人員執(zhí)行的PM作業(yè)目的:預防機器故障在發(fā)