一份國(guó)外公司的TPM講義課件(-62張)

1、A STRATEGY FORPERFORMANCE EXCELLENCETotal Productive Maintenance1Total Productive Maintenance1Performance Excellence SeriesTraining Module ElementsExecutive OverviewParticipant manualTools WorkbookKnowledge BreakthroughLecture notesLecture notes2Performance Excellence SeriesETable of ContentsExecuti

2、ve OverviewSession 1.0Introduction.3Session 2.0Role in Lean Manufacturing.8Session 3.0Role of the Operator in TPM.18Session 4.0Autonomous Maintenance Implementation22Session 5.0Equipment Performance: Measurement & Management.56TPM3Table of ContentsSession 1.0ITotal Productive MaintenanceDo these pro

3、blems sound familiar?Equipment is always breaking downOperating machines at rated speeds creates defectsSetups and adjustments take too longMinor machine stoppages are eroding productivity4Total Productive MaintenanceDoTotal Productive MaintenanceA series of methods to ensure that process machines a

4、re always able to perform their functions so that production is never interrupted.5Total Productive MaintenanceA Total Productive MaintenanceWhat it is:1. Optimizes equipment efficiency2. Implements a company wide Preventive Maintenance system3. Involves production equipment designers, operators, an

5、d maintenance department personnel4. Involvement from Management down to floor workers5. Implemented through small, self directed team activities6Total Productive MaintenanceWhTotal Productive MaintenanceTypical success results after implementation of TPM:Breakdowns:1/30 to 1/100 of prior levelMachi

6、ne defects: 1/30 to 1/40 of prior levelProductivity:30 - 100 percent increasesource: K. Shirose, TPM For Workshop Leaders, p. 107Total Productive MaintenanceTyPerformance Excellence:Expanding the Strategy through TPMIntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintena

7、nce ImplementationEquipment Performance: Measurement and ManagementTPM8Performance Excellence:TPM8The Nine types of wasteOverproductionDelays (waiting time)TransportationProcessInventoriesMotionsDefective productsUntapped resourcesMisused resources 9 WastesTPM targets reduction of these equipment or

8、iented wastes9The Nine types of wasteOverproYesterday:Problem = machine breakdown = get around the problemSolution = Work in batches“We use the time it works to mass produce”TPM: A Lean Manufacturing MethodTPM and one-piece flow:Today:Objective = One piece flow Quality every timeMeans = TPM“We organ

9、ize so it works continuously”10TPM: A Lean Manufacturing MethGoals of TPMAchieve zero equipment breakdowns and zero defects through prevention.Establish prevention by Maintaining normal conditions Early detection of abnormalities Quick response 11Goals of TPMAchieve zero equipPresent ConditionsOpera

10、tors view machines as responsible for major productionAnd limit their roles to equipment operation and inspecting for qualityWhile maintenance workers view their function as responding to recurring breakdowns 12Present ConditionsOperators viMaintenance ApproachesTime Based or Planned Maintenance - P

11、eriodically scheduled maintenance actions.Predictive Maintenance - Maintenance action performed resulting from evaluation of equipment condition. Corrective Maintenance - Maintenance action performed to restore optimal equipment function.Preventive Maintenance - A combination of Time based and Predi

12、ctive Maintenance and actions taken to sustain optimal equipment performance and preclude breakdowns. 13Maintenance ApproachesTime BasEarly Equipment Management Optimizes equipment selection through:Equipment Life Cycle Cost Analysis : analysis of the sum of all costs (direct and indirect) associate

13、d with an item of equipment throughout its period of use. MP Design: activity which is focused on minimizing future maintenance costs and production losses of equipment at the design stage.14Early Equipment Management OpTotal Productive MaintenanceWithout TPMWith TPMMED & Industrial EngineeringMaint

14、enanceMED & Industrial EngineeringOperationMaintenanceThe operator operates, maintenance maintains, etc.Shared responsibilitiesOperation15Total Productive MaintenanceWiEquipment Maintenance ResponsibilitiesOperationMaintenanceMED & Industrial EngineeringAutonomous maintenanceBreakdown maintenancePla

15、nned maintenancePredictive maintenanceMaintenance prevention16Equipment Maintenance ResponsiTotal Productive MaintenanceTPMEquipment in better working conditionDecrease of breakdownsDecrease of in-process adjustmentsOptimization of operation speedManufacturing defectsLead-timeQuality the first time1

16、7Total Productive MaintenanceTPPerformance Excellence:Expanding the Strategy through TPMIntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance: Measurement and ManagementTPM18Performance Excellence:TPM18Total Productive Maintenance

17、TPM, the total approachThe operator is the first line caretakerMaintenance personnel are the specialized caretakers.19Total Productive MaintenanceTPDivision of Maintenance Duties betweenProduction and MaintenanceDepending on knowledge and skills required, responsibility for equipment maintenance tas

18、ks needs to be defined: Maintenance TechnicianProduction Operator* Equipment overhaul* Basic lubrication* Special skill tasks* General cleaning* Complex adjustments* Multi-point inspection* High safety risk tasks* Basic adjustments20Division of Maintenance DutiesMaintenance Task Allocation betweenPr

19、oduction and MaintenanceMaintenanceTechniciansProductionOperatorsAutonomous maintenance implementationVolume of maintenance tasks21Maintenance Task Allocation bePerformance Excellence:Expanding the Strategy through TPMIntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Mainte

20、nance ImplementationEquipment Performance: Measurement and ManagementTPM22Performance Excellence:TPM22Autonomous means “independent”Autonomous maintenance refers to activities involving operators in the maintenance of their own equipment.Autonomous Maintenance23Autonomous means “independent”Autonomo

21、us MaintenanceHow to make the operator more independent:Make the documentation available (manual, maintenance schedule, log book).As a team, define manufacturing/maintenance/MED productive maintenance activities.Show operator how to perform daily checks and take corrective actions.Train in basic ope

22、ration, maintenance and defect detection techniques.Make daily activities visibleClearly identify items to supervise24Autonomous MaintenanceHow to mProcess Critical Machinery & EquipmentMap the process and identify critical equipmentTurningDrillingCuttingCleaningStripping& PaintingShipping25Process

23、Critical Machinery & EAdverse effects of inadequate cleaning26Adverse effects of inadequate Adverse effects of inadequate cleaning:Failure - equipment failure resulting from dirt and contamination affecting precisionProduct defects - contamination of products or defects arising from insufficient cle

24、aningAccelerated deterioration - dirt and scale buildup shortening useful equipment lifeThroughput loss - reduction in output due to loss of operation speed due to grime and contamination.27Adverse effects of inadequate Equipment DeteriorationNormal deterioration: deterioration that occurs despite c

25、orrect use and maintenanceAccelerated deterioration: quicker deterioration occurring due to misuse in operation and neglect of maintenance. 28Equipment DeteriorationNormal PerformanceTimeEquipment Breakdown100%Time and Deterioration of PerformanceNeed for detection of performance decline29Performanc

26、eTimeEquipment BreakCleaning as Detection of DeteriorationCleaning - reduces accelerated deteriorationPhysical contact with equipment - exposes abnormal operating conditions (i.e. vibration, noisy bearings, leaks, overheating, frayed belts, inoperative indicators, etc.)Preventive action taken - exte

27、nds useful life and avoids breakdowns30Cleaning as Detection of DeterA good clean-up allows for a good inspectionNoiseVibrationHeatOilDirtQuickly detectAnd documentCleaning as Detection of Deterioration31A good clean-up allows for a g Factors Contributing to Equipment Failure:Equipment failuresLoose

28、 partsVibrationContaminationImproper/InadequateLubrication32 Factors Contributing to Equip Eliminate Factors Contributing to Failure: Secure and tighten all fasteners, fittings, bolts and screws Replace any missing parts Replace any damaged, worn or wrong size parts Resolve all causes of leaks, spil

29、lage, spray and scatterImprove accessibility in order to accomplish Cleaning Lubricating Adjusting Checking33 Eliminate Factors ContributinTotal Productive MaintenanceSelf Maintenance - Operator_Equipment DescriptionI.D.#_Date:_Found by:_Description:Description:Total Productive MaintenanceSelf Maint

30、enance - Maintenance_Equipment DescriptionI.D.#_Date:_Found by:_Autonomous Maintenance: Tagging Abnormalities34Description:Description:AutonoTagging AbnormalitiesCleaning will uncover problems and undesirable conditions.Attach tag to make problem visibleResolves problems promptly and remove tags.Doc

31、ument plans to address those that cant be removed immediately.Autonomous Maintenance35Tagging Cleaning will uncover Before Tags are Removed, Ask The 5 “Whys”P(pán)roblem: Oil leaks from the hydraulic press1. Why? Clogged filter2. Why? Oil was dirty3. Why? Metal filings got into oil4. Why? Oil fill cap mi

32、ssing5. Why? Misplaced & lostFind the root causeSolution! Oil filler cap attached to filler neck by a chain (Poka-Yoke)36Before Tags are Removed, Ask TEquipment Performance LossesDowntime losses - time lost to equipment breakdowns, machine adjustmentsEfficiency losses - time lost to start up and ope

33、rating cycle speeds less than idealDefect losses - time lost to machine related quality defects and recycling. 37Equipment Performance LossesDoEquipment Performance Losses38Equipment Performance Losses38Assignable Loss versus Common LossDefect rateTimeAssignable loss - corrected by restoring to orig

34、inal conditionsCommon loss - reduced by achieving optimal conditions39Assignable Loss versus CommonImportance of LubricationSome experts estimate 60% of machine breakdowns associated with moving parts are due to lack of or improper lubrication practices.40Importance of LubricationSome Lubrication Ma

35、nagement ?The need to lubricate equipment correctly and consistentlyaccording to usagewith correct lubricantsin the correct amountat specified fittingsat specified time intervalsensuring coverage of contact areas41 Lubrication Management ?TheVisual Management of LubricantsGreenBlueOrangeRed w/ White

36、 stripeOilGreaseHydraulic fluidSilicone42Visual Management of LubricantMaintenance ChecklistsTPM VERIFICATION LISTAt The Beginning of Each ShiftHydraulic Pressure Leaks (oil, fluids)Caps and hosesSwitchesLights and lampsBodyNoises/vibrationAt The End of Each ShiftCleanMake entry in maintenance book4

37、3Maintenance ChecklistsTPM VERI12345678910Example Cleaning and Lubrication for Autonomous Maintenance4412345678910Example Cleaning anBasic Training in EquipmentConduct equipment training for leaders.Leaders then train group members.Operators implement training to correct abnormalities and improve eq

38、uipment performance.Implement visual controls.45Basic Training in EquipmentConExample Skills MatrixBasic Training in EquipmentOperation102030405060Equipment typeSMDChip-shooterCut & ClinchPin & BushingWave solderPost-Wave Wash David B.Linda W.Matt S.Debbie M.Steve H.John S.Jessica L.Legend:Knows bas

39、ics Can do with help Can do w/o help Can teach someone elsePrinted Circuit Assembly Equipment Specialists46Example Skills MatrixBasic TraOne Point LessonPurpose: To provide specific knowledge about a single topic of importance. Facilitate team training in an easy manner.Discussed on the shop floor.T

40、ypes:KnowledgeImprovementsSolutions to problems47One Point LessonPurpose: 47Object Name: Fasteners Subject: IdentificationNumber: Generic typesDate prepared: 4/17/00By: John ClarkApproved: Tina JonesOne-Point Lesson SheetDepartmentDate trainedNamePurpose: Identification of fastener hardware for repa

41、irs and ordering of replacements.Maint.PurchasingInventory StoresType: KnowledgeProblemImprovementxOne Point LessonProduction48Object Name: Fasteners TPM Deployment Effectiveness through Overlapping TeamsPlant ManagerStaff ManagerStaff ManagerStaff ManagerDept. ManagerDept. ManagerDept. ManagerSuper

42、visorSupervisorSupervisorSupervisorOperatorOperatorOperatorOperatorOperatorMaximizing Communication &CoordinationTeam leaders49TPM Deployment Effectiveness tBuild a Time Based Maintenance SystemDetermine equipment for time based maintenanceDevelop maintenance criteria and intervalsTrain for maintena

43、nce implementationExecute periodic maintenance Was maintenance effective?NoRevise maintenance instructions / parts provisioning50Build a Time Based MaintenanceEstablish an Equipment Failure DatabaseGather and manage equipment failure information.Analyze for trends and patterns of recurrence.Develop

44、and issue periodic equipment failure summary reports.Include failure summary reports as a meeting agenda item for regular review, discussion and improvement action planning. 51Establish an Equipment FailurePredictive Maintenance as a Diagnostic Tool52Predictive Maintenance as a 52Predictive Maintena

45、nce DeploymentDetermine equipment suitable for Predictive MaintenanceDevelop diagnostic methods and instructionsDiagnose equipment as definedExecute repair Repair/Overhaul Needed?YesRevise maintenance instructions / parts provisioningDocument repair informationEvaluate and revise diagnostic criteria

46、53Predictive Maintenance DeploymMaintenance Audits Audits are the most important factor in the successful implementation of an Autonomous Maintenance Program. They :Verify success of implementation at each stepProvide improvement feedbackInstill a sense of achievement and reinforce continuing effort

47、 toward goals 54Maintenance Audits Audits Maintenance Audits Implementation of autonomous maintenance group activitiesRequest for audit forwarded to TPM coordinatorAudit performedResults documentedPost audit meeting conductedAudit action items addressedPassedYesNoCongratulate TeamBegin implementatio

48、n of next TPM activityExample Audit Cycle 55Maintenance Audits ImplementatPerformance Excellence:Expanding the Strategy through TPMIntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance: Measurement and ManagementTPM56Performance E

49、xcellence:TPM56Overall Equipment Effectiveness Overall Equipment Effectiveness = Availability x Efficiency rate x Quality rateAn index of the overall operating performance of equipmentPoints to the need to Eliminate stoppagesIncrease operating speed.Improve quality (less defects, rework, scrap)57Ove

50、rall Equipment EffectivenesEquipment effectiveness measurementDowntime lossesEfficiency lossesDefect lossesAvailability = (Shift time - non-operating time) - downtime Shift time - non-operating timeQuality rate = Production quantity - defectivesProduction quantity Efficiency rate = measured producti

51、on rate standard production rateEquipment breakdownsSet-ups and adjustmentsEquipment actual speed versus rated speedQuality defectsOverall Equipment Effectiveness = Availability x Efficiency rate x Quality rate 58Equipment effectiveness measurTracking Improvement Impacts On Overall Equipment Effecti

52、venessBreakdown reductionsSet-up reductionsRework reductionsImproved equipment speedsDefect reductionsImprovement Activities59Tracking Improvement Impacts OThe Mission Board : A Roadmap to ActionMission BoardTeam Name _Leader: _Members: _ _ _ _Mission:_ _ _Targets: _ _ _ Solder Overall Wave Effectiv

53、eness AvailabilityEfficiencyQualityActions:_ _ _Evaluation:_ _ _Results: _ _ _60The Mission Board : A Roadmap Maintenance Information Management System Maintenance Information Management SystemOverall Equipment EffectivenessCost accountingLabor & material costsMaterial ControlUsage and inventoryHuman ResourcesStaffing & skills requirementsQuality Assurance Product quality ProductivityMaintenance information in relation to other business process systems 61Maintenan