全員生產(chǎn)保養(yǎng)

1、Time Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 2 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB TPM概略概略 TPM Overview TPM

2、目的目的 The Aim of TPM TPM流程流程 TPM Process 自主保養(yǎng)自主保養(yǎng) Autonomous Maintenance 計劃保養(yǎng)計劃保養(yǎng) Planned Maintenance 預(yù)防工程預(yù)防工程 Preventive Engineering 教育與行動教育與行動 Education & Practice 保證質(zhì)量保證質(zhì)量 Insured Quality TPM改善活動改善活動 TPM Kaizen Activities TPM活動進(jìn)階活動進(jìn)階 Advanced TPM ActivitiesTime Based ManagementP SKB 2008 TBM Consu

3、lting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 4 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB是這樣一個系統(tǒng)是這樣一個系統(tǒng)otal roductive aintenance is a system that 涉及工場涉及工場

4、/ 維修人員維修人員Involves both shopfloor associates and maintenance associates 支持支持精益西格瑪流程精益西格瑪流程Supports the LeanSigma Process 保持設(shè)備最佳狀態(tài)保持設(shè)備最佳狀態(tài)Keeps equipment in optimal condition 8 - 5 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 忽視設(shè)備基本狀況忽視設(shè)備基本狀況Basic Equipment conditions neglected 操作維修技能欠佳操

5、作維修技能欠佳Insufficient operating and maintenance skills 設(shè)備設(shè)計固有不足設(shè)備設(shè)計固有不足Inherent weakness in equipment design 設(shè)備惡化無人監(jiān)督設(shè)備惡化無人監(jiān)督Overlooked deterioration 沒有遵守使用要求沒有遵守使用要求Usage conditions not observed 8 - 6 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBTPM世界性的公司世界性的公司W(wǎng)orld Wide Company工人自主保養(yǎng)工人自主

6、保養(yǎng)OperatorAutonomousMaintenance預(yù)防保養(yǎng)預(yù)防保養(yǎng)Preventive Maintenance經(jīng)理支持功能經(jīng)理支持功能ManagerSupportFunction工程設(shè)備工程設(shè)備設(shè)計改善設(shè)計改善Eng. Equip.DesignImprovement品質(zhì)改善品質(zhì)改善QualityImprovement全員生產(chǎn)保養(yǎng)全員生產(chǎn)保養(yǎng)T P M高級管理層高級管理層領(lǐng)導(dǎo)領(lǐng)導(dǎo) S M L生產(chǎn)準(zhǔn)備生產(chǎn)準(zhǔn)備2P西格瑪改善西格瑪改善Sigma Kaizen8 - 7 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 零故

7、障零故障 Zero Breakdowns 零缺陷零缺陷 Zero Defects 零事故零事故 Zero Accidents 全員參與全員參與 Total employee involvement 提高機器效率提高機器效率, 滿足節(jié)拍滿足節(jié)拍速度速度Achieve Takt Rate at the highest machine effectiveness 8 - 8 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB機器可靠機器可靠Machine Reliability機器高效機器高效Machine Effectiveness聯(lián)

8、動操作聯(lián)動操作Linked Operations人力利用人力利用Labor Utilization制程能力制程能力Process Capability最佳機況最佳機況Optimal machine conditions制程重復(fù)制程重復(fù)Process Repeatability防錯裝置防錯裝置Mistake Proofing8 - 9 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB每班每班8小時小時 8 hr shift有效時間有效時間 = 7小時小時40分分 Effectiveness = 7 hrs 40min工人開會工人開

9、會: 10分鐘分鐘Operator Meeting10 min10 min設(shè)備清潔與潤滑設(shè)備清潔與潤滑: 10分鐘分鐘Equipment cleaning & Lubrication 本班開始本班開始 Shift Start品質(zhì)問題品質(zhì)問題 Quality暫停暫停 Minor Stoppages故障停機故障停機 Breakdown調(diào)整調(diào)整 Adjustment本班結(jié)束本班結(jié)束 Shift End每班每班8小時小時 8 hr shift有效時間有效時間 = 6小時小時 Effectiveness = 6 hrs8 - 10 2008 TBM Consulting Group, Inc. All

10、Rights Reserved.P SKB整體設(shè)備效率整體設(shè)備效率 Overall Equipment Effectiveness (OEE) 可用效率可用效率 Availability 性能效率性能效率 Performance 品質(zhì)效率品質(zhì)效率 Quality保養(yǎng)效率保養(yǎng)效率 Maintenance Effectiveness 平均故障時間間隔平均故障時間間隔 MTTF (Mean time to failure) 平均無故障時間平均無故障時間 MTBF (Mean time between failure) 平均維修時間平均維修時間 MTTR (Mean time to repair)Ti

11、me Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc. 改善設(shè)備運行狀況改善設(shè)備運行狀況To improve the equipment operating condition 維持設(shè)備最佳性能與可靠性維持設(shè)備最佳性能與可靠性To s

12、ustain equipment at an optimal level of performance & reliability 延長設(shè)備使用壽命延長設(shè)備使用壽命To lengthen the life expectancy of equipment Time Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered

13、trademarks of TBM Consulting Group Inc.8 - 13 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB自主保養(yǎng)自主保養(yǎng) Autonomous Maintenance計劃保養(yǎng)計劃保養(yǎng)PlanningMaintenance預(yù)防工程預(yù)防工程PreventiveEngineering品質(zhì)品質(zhì)Quality 教育與行動教育與行動Education& Practice8 - 14 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB1.測量工

14、作單元上所有自動設(shè)備之測量工作單元上所有自動設(shè)備之OEEMeasure OEE for all automatic equipment in cells. 2.測量各工作單元的節(jié)拍時間測量各工作單元的節(jié)拍時間Measure Takt rate performance for each area. 3.將單元節(jié)拍時間與設(shè)備將單元節(jié)拍時間與設(shè)備OEE進(jìn)行比較進(jìn)行比較Correlate cell takt rate performance to equipment OEE. 4.選擇特定機器作為改善重點選擇特定機器作為改善重點Select specific machine for kaizen fo

15、cus. 5.根據(jù)根據(jù)OEE六大損失制定改善目標(biāo)六大損失制定改善目標(biāo)Establish improvement goal related to the six major losses of OEE.6.選定設(shè)備改善專職隊員選定設(shè)備改善專職隊員Select permanent equipment improvement team members.7.發(fā)動工人進(jìn)行自主保養(yǎng)及計劃保養(yǎng)活動發(fā)動工人進(jìn)行自主保養(yǎng)及計劃保養(yǎng)活動Initiate operator autonomous maintenance and planned maintenance programs. 8.繼續(xù)更新檢查單繼續(xù)更新檢查

16、單, 培訓(xùn)工人培訓(xùn)工人, 保證機器最佳狀況保證機器最佳狀況Continue to update check lists, train operators, and pursue optimal machine conditions. 9.為選定設(shè)備設(shè)立為選定設(shè)備設(shè)立TPM活動之目視表現(xiàn)板活動之目視表現(xiàn)板Establish visual performance boards for TPM activities on selected equipment. 10.每月將改善目標(biāo)與實際結(jié)果進(jìn)行比較。評價是否需要進(jìn)行更多改善活動每月將改善目標(biāo)與實際結(jié)果進(jìn)行比較。評價是否需要進(jìn)行更多改善活動, 制定更

17、制定更高的目標(biāo)高的目標(biāo), 或需要更換專職隊員或需要更換專職隊員Check results to improvement goals monthly. Evaluate need for additional kaizen activity, setting more aggressive goals, or modifying permanent team members. Time Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, L

18、eanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 16 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB工人要學(xué)習(xí)工人要學(xué)習(xí) A system where equipment operators learn to : 進(jìn)行每日檢查進(jìn)行每日檢查 Perform daily checks 按需潤滑設(shè)備按需潤滑設(shè)備 Lubricate equipment as needed 更

19、換簡單零件更換簡單零件 Replace simple components 進(jìn)行機器小修進(jìn)行機器小修 Perform minor repairs on machines 幫助解決問題幫助解決問題 Assist in problem solving8 - 17 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB1.進(jìn)行基本清潔活動進(jìn)行基本清潔活動Perform basic cleaning 2.根除骯臟污染源頭根除骯臟污染源頭Eliminate sources of dirt and contamination 3.建立清潔潤滑標(biāo)準(zhǔn)

20、建立清潔潤滑標(biāo)準(zhǔn)Establish cleaning and lubrication standards 4.教會設(shè)備基本檢查教會設(shè)備基本檢查, 進(jìn)行自主設(shè)備檢查進(jìn)行自主設(shè)備檢查Teach general inspection of equipment and Perform autonomous equipment inspection 5.培養(yǎng)整齊有序習(xí)慣培養(yǎng)整齊有序習(xí)慣Instill orderliness and organization 8 - 18 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 預(yù)防污染預(yù)防污染

21、Prevent deterioration : 維持基本條件維持基本條件Maintaining basic conditions 正確操作設(shè)備正確操作設(shè)備Operating equipment correctly 判斷污染判斷污染Measure deterioration : 進(jìn)行檢查進(jìn)行檢查Inspecting 制定標(biāo)準(zhǔn)制定標(biāo)準(zhǔn), 堅持執(zhí)行堅持執(zhí)行Developing and adhering to standards 糾正污染糾正污染Correct deterioration : 報告問題報告問題Reporting problems 協(xié)助維修協(xié)助維修Assisting in repairs

22、 進(jìn)行微調(diào)進(jìn)行微調(diào) (按本地合約按本地合約)Making minor adjustments (per local contract) 加入團隊加入團隊Participate in teams : 工作中心團隊工作中心團隊Work center teams 解決問題團隊解決問題團隊Problem-solving teams 8 - 19 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 設(shè)備保養(yǎng)設(shè)備保養(yǎng)Maintain Equipment 檢驗檢驗 (拆卸拆卸)Inspect (disassembly) 計劃保養(yǎng)計劃保養(yǎng)Plan

23、ned overhauls 預(yù)防保養(yǎng)預(yù)防保養(yǎng)Preventive maintenance 教導(dǎo)工人學(xué)會特定保養(yǎng)工作教導(dǎo)工人學(xué)會特定保養(yǎng)工作Teach selected maintenance tasks to operators 設(shè)備改善設(shè)備改善Improve Equipment 支持可靠性及可維修性改善支持可靠性及可維修性改善Support R&M improvement 實施預(yù)測技術(shù)實施預(yù)測技術(shù)Implement predictive technologies 糾正設(shè)計不足糾正設(shè)計不足Correct design weaknesses 搞好供方合作搞好供方合作Partner with ve

24、ndors 8 - 20 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 初步清潔初步清潔 Initial Cleaning 螺母、螺栓等有無松動、搖擺、遺失螺母、螺栓等有無松動、搖擺、遺失?Any nuts, bolts, etc. loose, wobbly or missing? 活動零件、夾具安裝有無竄動活動零件、夾具安裝有無竄動?Any play in moving parts or fixture mounting section? 機器內(nèi)部有無多余零件機器內(nèi)部有無多余零件?Any unnecessary item

25、s located on the body of the machine? 潤滑系統(tǒng)潤滑系統(tǒng) Lubrication 潤滑油是否到達(dá)滑動部件潤滑油是否到達(dá)滑動部件? Does oil reach sliding parts? 潤脂嘴、機油蓋等是否損壞、遺失潤脂嘴、機油蓋等是否損壞、遺失?Any damaged or missing grease nipples, oil caps, etc.? 供油裝置、管路、接頭有無漏油供油裝置、管路、接頭有無漏油?Any oil or grease leaks from supply devices, pipes, fittings? 加油工人有無內(nèi)外清潔

26、加油工人有無內(nèi)外清潔? Are oilers clean inside or out? 油標(biāo)是否容易看見油標(biāo)是否容易看見? Is the oil level easily visible? 8 - 21 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 液壓系統(tǒng)液壓系統(tǒng) Hydraulics 油箱裝夠油了嗎油箱裝夠油了嗎? Is the oil tank filled to the specified level? 油泵發(fā)出異常噪音嗎油泵發(fā)出異常噪音嗎? Is the pump emitting any abnormal noi

27、ses? 卸荷閥、減壓閥、節(jié)流閥防松螺母上緊了嗎卸荷閥、減壓閥、節(jié)流閥防松螺母上緊了嗎?Are locknuts tight on relief, reducing and throttle valves? 卸荷閥、控制裝置運作正常嗎卸荷閥、控制裝置運作正常嗎?Are relief valves and controls operating correctly? 高壓管路連接變形或磨損了嗎高壓管路連接變形或磨損了嗎?Any strain or wear in high pressure hose connections? 電器系統(tǒng)電器系統(tǒng) Electrical 行程開關(guān)杠桿能夠完全接觸嗎行程開

28、關(guān)杠桿能夠完全接觸嗎? Do limit switch bars strike fully? 信號燈、指示燈遺失或燒壞了嗎信號燈、指示燈遺失或燒壞了嗎?Any missing or burned out pilot or indicator lights? 配電盤、電器箱有無線路圖配電盤、電器箱有無線路圖?Are there wiring diagrams in the control panels or electrical boxes? 有無多余的、損壞的、壓壞的電線或軟管有無多余的、損壞的、壓壞的電線或軟管?Any unnecessary, damaged or dented wires

29、 or flexible tubing? 8 - 22 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 傳動系統(tǒng)傳動系統(tǒng) Power Transfer Devices V型皮帶碰到帶輪槽底了嗎型皮帶碰到帶輪槽底了嗎?Do V-belts hit the bottom of pulley grooves? 皮帶有無損壞、爆裂、破裂皮帶有無損壞、爆裂、破裂?Any damage, cracking or splitting of the belts? 滾柱鏈條的銷軸與軸承之間有無足夠潤滑油滾柱鏈條的銷軸與軸承之間有無足夠潤滑油?I

30、s there sufficient lubrication between pins and bushings of roller chains? 轉(zhuǎn)軸有無過熱、振動、噪音轉(zhuǎn)軸有無過熱、振動、噪音?Any shaft overheating, vibration or noise? 聯(lián)接系統(tǒng)有無鎖鍵、夾緊螺栓松動造成的竄動聯(lián)接系統(tǒng)有無鎖鍵、夾緊螺栓松動造成的竄動?Any play due to loose keys or clamping bolts on couplings? 齒輪機構(gòu)有無過量的躁音、發(fā)熱、振動齒輪機構(gòu)有無過量的躁音、發(fā)熱、振動?Any excess noise, heat

31、 or vibration in gear mechanisms? 8 - 23 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 螺母螺栓螺母螺栓 Nuts and Bolts 登記記號允許松緊度檢查嗎登記記號允許松緊度檢查嗎?Do registration marks permit tightness checks? 螺母螺栓型號及尺寸正確嗎螺母螺栓型號及尺寸正確嗎?Are nuts and bolts of the suitable types or sizes used? 墊片尺寸正確墊片尺寸正確, 且類型相配嗎且類型相

32、配嗎?Are washers of proper size, and are they consistently used? 螺栓有從螺母凸出螺栓有從螺母凸出23圈螺紋嗎圈螺紋嗎?Do bolts protrude 2 3 threads from the nuts? 氣動系統(tǒng)氣動系統(tǒng) Pneumatics 截止閥及球閥漏氣嗎截止閥及球閥漏氣嗎? Any stop valve, ball valve leaks? 有壞了或多余的手把嗎有壞了或多余的手把嗎? Any broken or unnecessary handles? 已關(guān)閉的閥仍有氣流嗎已關(guān)閉的閥仍有氣流嗎? Does any air

33、 flow through closed valves? 有任何不必要的裝置或喉管嗎有任何不必要的裝置或喉管嗎?Are any unnecessary devices, hoses or pipes present? 所有喉管都整齊及易于識別嗎所有喉管都整齊及易于識別嗎?Are pipes and hoses orderly and readily identifiable? 壓力表指示的都是正確設(shè)定的壓力嗎壓力表指示的都是正確設(shè)定的壓力嗎?Do pressure gauges clearly indicate the correct set pressure? 8 - 24 2008 TBM

34、 Consulting Group, Inc. All Rights Reserved.P SKB 做好清潔檢查做好清潔檢查 Clean to inspect 暴露隱藏不足暴露隱藏不足 Expose hidden defects 找出臟污源頭找出臟污源頭 Determine source of contamination 識別難于清潔之處識別難于清潔之處 Identify hard to reach areas 準(zhǔn)備藍(lán)色標(biāo)簽工作準(zhǔn)備藍(lán)色標(biāo)簽工作 Prepare for blue tag exercise8 - 25 2008 TBM Consulting Group, Inc. All Rig

35、hts Reserved.P SKB臟污原因臟污原因 Causes of Contamination: 發(fā)生液體泄漏發(fā)生液體泄漏 Fluid leaks 碎片容器很差碎片容器很差 Poor chip containment 工作不佳工作不佳 Poor 5S practices 工作區(qū)有濺灑工作區(qū)有濺灑 Work area spills 過濾性能不好過濾性能不好 Poor filtration 沒有清潔標(biāo)準(zhǔn)沒有清潔標(biāo)準(zhǔn) No cleaning standards 無工作自豪感無工作自豪感 Poor work pride 環(huán)境問題惡劣環(huán)境問題惡劣 Environment 8 - 26 2008 T

36、BM Consulting Group, Inc. All Rights Reserved.P SKB 從工人開始進(jìn)行基本的清潔、檢查及潤滑活動從工人開始進(jìn)行基本的清潔、檢查及潤滑活動Begin basic operator cleaning, inspecting and lubricating activities 制定臨時標(biāo)準(zhǔn)制定臨時標(biāo)準(zhǔn) Establish provisional standards 進(jìn)行重點訓(xùn)示進(jìn)行重點訓(xùn)示 Create one point lesson 確定活動頻次確定活動頻次 Establish frequency of activities 月檢、周檢、日檢清單

37、月檢、周檢、日檢清單Monthly, weekly and daily check list 制做檢查表制做檢查表 Develop check list 8 - 27 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB1.0 目的目的/范圍范圍: 根據(jù)根據(jù)3600路線檢查單脂具體檢查步驟制定詳細(xì)的工作指示路線檢查單脂具體檢查步驟制定詳細(xì)的工作指示2.0 責(zé)任責(zé)任: 工人工人3.0 安全安全: 標(biāo)準(zhǔn)的工人保護設(shè)備標(biāo)準(zhǔn)的工人保護設(shè)備: 防護眼鏡防護眼鏡, 聽覺保護用具聽覺保護用具, 手套手套, 鋼頭鞋鋼頭鞋4.0 工作指示工作指示第第

38、1步步: 本工作指示用于與本工作指示用于與3600路線檢路線檢查單有關(guān)的工作查單有關(guān)的工作第第2步步: 本工作指示用于本工作指示用于3600噸沖壓機噸沖壓機周圍的檢查工作周圍的檢查工作35第第3步步: 檢查模具加熱爐溫度及設(shè)定值。檢查模具加熱爐溫度及設(shè)定值。絕對最低設(shè)定值應(yīng)為絕對最低設(shè)定值應(yīng)為800度度8 - 28 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 制定詳細(xì)的培訓(xùn)計劃制定詳細(xì)的培訓(xùn)計劃Develop in depth training program 對工人就以下內(nèi)容進(jìn)行培訓(xùn)：對工人就以下內(nèi)容進(jìn)行培訓(xùn)：Train

39、 operators in: 潤滑作用潤滑作用/粘性分析粘性分析 Lubrication/ Viscosity Analysis 氣動系統(tǒng)氣動系統(tǒng) Pneumatics 液壓系統(tǒng)液壓系統(tǒng) Hydraulic 電氣系統(tǒng)電氣系統(tǒng) Electrical systems 驅(qū)動系統(tǒng)驅(qū)動系統(tǒng) Drive systems 修改目前的重點訓(xùn)示修改目前的重點訓(xùn)示, 加入檢驗檢查工作加入檢驗檢查工作Revise existing one-point lessons to include inspection checks 8 - 29 2008 TBM Consulting Group, Inc. All Rig

40、hts Reserved.P SKB 工場管理與控制工場管理與控制 Workplace management & control 擴展團隊活動擴展團隊活動, 做好設(shè)備以外的整潔工作做好設(shè)備以外的整潔工作Expand team activities beyond equipment to other aspects of the process 搞好工場整潔搞好工場整潔, 實行目視控制，發(fā)現(xiàn)改善機會實行目視控制，發(fā)現(xiàn)改善機會 (第第4、5個個S)Expose opportunities for improved organization, orderliness and visual contr

41、ol (4th & 5th S) 進(jìn)行進(jìn)行5S評審評審 Perform 5S audits 8 - 30 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB8 - 31 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 寫出已做的活動寫出已做的活動, 展示取得的進(jìn)步展示取得的進(jìn)步Describes activities undertaken and shows progress 對比制定的標(biāo)準(zhǔn)對比制定的標(biāo)準(zhǔn), 量化取得的改善量化取得的改善 故障停機、維修呼故障停機、

42、維修呼叫、停線時間等叫、停線時間等Quantifies the improvements made against agreed metrics. e.g. (Breakdowns, defects, maintenance call-outs, line down-time, etc.) 細(xì)化實際的改善細(xì)化實際的改善 Details the actual improvements made 記錄待研究項目記錄待研究項目 Records issues to be reviewed: 沒有答復(fù)的問題沒有答復(fù)的問題 Unanswered questions 需要支援的問題需要支援的問題 Compl

43、ex issues support required 8 - 32 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB問題公報問題公報ProblemNewspaper問題公報問題公報ProblemNewspaper生產(chǎn)保養(yǎng)完成率生產(chǎn)保養(yǎng)完成率PM Completion Ratio8 - 33 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBTime Based ManagementP SKB 2008 TBM Consulting Group, Inc. All R

44、ights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 35 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB進(jìn)行進(jìn)行TPM基礎(chǔ)基礎(chǔ)知識培訓(xùn)，知識培訓(xùn)，評審準(zhǔn)備工評審準(zhǔn)備工作作Train in TPM fundamentals & Review Pre-work 實施藍(lán)色標(biāo)實施藍(lán)色標(biāo)簽

45、方法簽方法Conduct Blue Tag Exercise 異常情況排異常情況排序序Rank abnormalities 異常情況維異常情況維修修Repair abnormalities設(shè)備設(shè)備OEM手手冊評審冊評審Review equipment OEM manuals 確定工人自確定工人自主保養(yǎng)路線主保養(yǎng)路線, 制定檢查表制定檢查表Create Op. AM route & Check sheet 定義定義 / 實施標(biāo)實施標(biāo)準(zhǔn)化工作準(zhǔn)化工作Define & Implement Std Work 實現(xiàn)保養(yǎng)反饋實現(xiàn)保養(yǎng)反饋循環(huán)循環(huán)Implement feedback loop to main

46、tenance 進(jìn)行進(jìn)行OEE表現(xiàn)表現(xiàn)公告公告Implement OEE performance board 向管理層展向管理層展示結(jié)果示結(jié)果Presentation to Mgrs. 8 - 36 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 收集改善活動一個月前的停機數(shù)據(jù)收集改善活動一個月前的停機數(shù)據(jù)Collect downtime data for one month prior to event 進(jìn)行設(shè)備基本清潔活動進(jìn)行設(shè)備基本清潔活動Conduct initial cleaning of equipment 收集設(shè)

47、備規(guī)格、收集設(shè)備規(guī)格、OEM手冊、機器手冊、機器BOM及圖紙及圖紙Gather machine specifications, OEM manuals, machine BOM, blueprints 8 - 37 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 進(jìn)行兩小時的觀察進(jìn)行兩小時的觀察 Conduct two-hour observation 清潔臟污源頭清潔臟污源頭, 貼上藍(lán)色標(biāo)簽貼上藍(lán)色標(biāo)簽Clean and Blue Tag sources of dirt and contamination 集思廣益集思廣益

48、按實施難易程度排序按實施難易程度排序Brainstorm ideas Prioritize according to implementation ease 實施解決方案實施解決方案, 消除臟污源頭消除臟污源頭Implement solutions to eliminate sources of contamination 設(shè)計工人自主保養(yǎng)路線、檢查表及重點訓(xùn)示設(shè)計工人自主保養(yǎng)路線、檢查表及重點訓(xùn)示, 實現(xiàn)保養(yǎng)標(biāo)準(zhǔn)實現(xiàn)保養(yǎng)標(biāo)準(zhǔn)化化Standardize and develop Operator Autonomous Maintenance Routes, Check Sheets and On

49、e-point lesson 實行實行OEE表現(xiàn)公告制度表現(xiàn)公告制度 Implement OEE performance board 實施設(shè)備保養(yǎng)反饋循環(huán)實施設(shè)備保養(yǎng)反饋循環(huán)Implement equipment maintenance feedback loop 8 - 38 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB改善前改善前 Before改善后改善后 After8 - 39 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 識別臟污及異常源頭識別臟污

50、及異常源頭 Identify sources of contamination and malfunctions 每個源頭貼上藍(lán)色標(biāo)簽每個源頭貼上藍(lán)色標(biāo)簽 Write a blue tag for each identified item 在機器上靠近源頭處掛上藍(lán)色標(biāo)簽在機器上靠近源頭處掛上藍(lán)色標(biāo)簽Attach blue tag to machine at location of specific item 在總表上記錄藍(lán)色標(biāo)簽資料在總表上記錄藍(lán)色標(biāo)簽資料Document Tag Information on Summary Chart 與保養(yǎng)人員評審藍(lán)色標(biāo)簽與保養(yǎng)人員評審藍(lán)色標(biāo)簽, 按影響程

51、度及修理難易程度排序按影響程度及修理難易程度排序Review tags with maintenance personnel as a team & rank according to impact & difficulty of repair 改善活動期間沒有解決的異常問題改善活動期間沒有解決的異常問題, 保養(yǎng)人員要做好行動計劃保養(yǎng)人員要做好行動計劃, 列明負(fù)列明負(fù)責(zé)人及時間要求責(zé)人及時間要求Maintenance completes Who and When information for abnormalities not repaired during kaizen event and

52、 creates Action Plan 改善小組更新總表狀態(tài)改善小組更新總表狀態(tài) Team updates status of summary chart 在每月改善評審會議上在每月改善評審會議上, 專職隊員評審總表狀態(tài)專職隊員評審總表狀態(tài)Permanent team reviews status of summary chart at monthly kaizen review meeting 8 - 40 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBBlue Tag - (part 1)Number:36702Date

53、ShiftBy :Problem ElectricalOperationMechanicalInstrument / ControlLubricationUtility / FacilityOther _Brief Description of Problem:Blue Tag - (part 2)Number:36702DateShiftBy :Location / System / Equipment / Part I.D.Problem ElectricalOperationMechanicalInstrument / ControlLubricationUtility / Facili

54、tyOther _Description of Problem (continue on back):Possible Impact of Problem Availability (Uptime)WastePerformance / SpeedCostQuality of ProductSafetyEnviromentOther _Corrective Action Plan:W/O #By:Date:By:Date:By:Date:Root Cause / Action (continue on Back)Date Completed:_OK _藍(lán)色標(biāo)簽藍(lán)色標(biāo)簽藍(lán)色標(biāo)簽藍(lán)色標(biāo)簽第第1部分部

55、分第第2部分部分編號編號編號編號日期日期日期日期檢查人檢查人檢查人檢查人班次班次班次班次問題問題問題問題電氣電氣機械機械潤滑潤滑操作操作儀器儀器 / 控制機構(gòu)控制機構(gòu)設(shè)備設(shè)備其它其它問題簡述問題簡述電氣電氣機械機械潤滑潤滑操作操作設(shè)備設(shè)備儀器儀器 / 控制機構(gòu)控制機構(gòu)其它其它問題簡述問題簡述, 繼續(xù)見背面繼續(xù)見背面問題可能影響問題可能影響可使用時間可使用時間性能性能/速度速度成品質(zhì)量成品質(zhì)量環(huán)境環(huán)境浪費浪費成本成本安全安全其它其它改正行動計劃改正行動計劃執(zhí)行人執(zhí)行人執(zhí)行人執(zhí)行人執(zhí)行人執(zhí)行人日期日期日期日期日期日期工作單號工作單號根本原因根本原因 / 行動行動, 更多見背面更多見背面完成日期完成

56、日期位置位置 / 系統(tǒng)系統(tǒng) / 設(shè)備設(shè)備 / 零件代號零件代號8 - 41 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB8 - 42 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBNo.異常異常 Malfunction行動行動 Action負(fù)責(zé)人負(fù)責(zé)人Who 時間時間When OK1漏油漏油Oil leak重新設(shè)計油槽重新設(shè)計油槽, 引導(dǎo)及引導(dǎo)及接住導(dǎo)軌油接住導(dǎo)軌油Need chute designed to guide and catch way lube

57、 oil 保養(yǎng)人員保養(yǎng)人員 Maint. 4/18/912油泵油泵濾網(wǎng)濾網(wǎng)上金屬過上金屬過濾器蓋彎曲濾器蓋彎曲Metal filter cover over the pump screen bent 弄直或更換弄直或更換Straighten or replace 改善隊員改善隊員Team 4/10/91已完成已完成Complete3蓋外殼時遺失兩個蓋外殼時遺失兩個螺絲螺絲 Two screws missing on way cover housing更換更換Replace 改善隊員改善隊員 Team 4/18/91已完成已完成Complete4滑動門上軌道滾柱滑動門上軌道滾柱軸承遺失軸承遺失R

58、oller bearing missing on the top track of the sliding door更換更換Replace 保養(yǎng)人員保養(yǎng)人員 Maint. 4/21/915Nachi液壓泵底下漏液壓泵底下漏油油Oil leak at the base of the Nachi hydraulic pump檢查密封圈檢查密封圈, 必要時更必要時更換換 Check gasket, replace if needed保養(yǎng)人員保養(yǎng)人員 Maint. 5/13/918 - 43 2008 TBM Consulting Group, Inc. All Rights Reserved.P S

59、KB目的目的 Used To: 發(fā)現(xiàn)所有浪費跡象發(fā)現(xiàn)所有浪費跡象, 提出可能解決方案提出可能解決方案Capture waste information and potential solutions 按問題清晰程度及實施難易程度按問題清晰程度及實施難易程度, 將解決方案進(jìn)將解決方案進(jìn)行排序行排序Rate / rank the solutions in regards to resolution of the issues and ease of implementation 8 - 44 2008 TBM Consulting Group, Inc. All Rights Reserved.P

60、 SKBProcess:Communications Tech Support Call ProcessBarrier / WasteRoot CauseSolution / ImpactDifficultyImpact1172473474175110647717841091710771177127413101014101015107Call ProcessingComputer System TrainingOne on one trainingParts ProcessingNo quick reference materialsNo access to ImpromptuNo Stand