精益生產(chǎn)之全面生產(chǎn)維護(hù)課件

全面生產(chǎn)維護(hù)

(TPM)TPMTPM團隊組織設(shè)備綜合利用率OEETPM活動步驟RD011202全面生產(chǎn)維護(hù)

(TPM)TPMRD011202TotalProductiveMaintenance(TPM)TPMTPMTeamOrganizationOverallEquipmentEffectivenessTPMPhasesRD011202TotalProductiveMaintenance(精益6

過程改善流程分析控制改進(jìn)定義選定題目列出客戶從顧客之聲中列出關(guān)建需求定出項目焦點和重要指標(biāo)完成PDF測量繪制業(yè)務(wù)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(guān)鍵因子區(qū)分關(guān)鍵因子驗證關(guān)鍵因子評枯每個關(guān)鍵因子對結(jié)果的影響量化機會根本原因排序?qū)ふ腋驹蜥槍﹃P(guān)鍵因子改進(jìn)關(guān)鍵因子確認(rèn)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(wù)過程指標(biāo)項目過渡給未來項目管理者項目鑒別轉(zhuǎn)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(fēng)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(yīng)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(fēng)暴拉系統(tǒng)減少設(shè)置TPM流程圖標(biāo)桿管理親和圖DOE假設(shè)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)精益6

過程改善流程分析控制改進(jìn)定義測量分析改進(jìn)控制測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)LeanSixSigma

ImprovementPr課程目的學(xué)習(xí)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(dǎo)致設(shè)備故障的因素;使設(shè)備的養(yǎng)護(hù)清潔更易達(dá)成;用預(yù)測性保養(yǎng)作為一種檢測工具;實施維護(hù)審查5TotalProductiveMaintenance(TPM)課程目的學(xué)習(xí)一種方法以便:5TotalProductiveLearningObjectivesLearnamethodto:IntegrateoperationalproductivityfactorsapplicableinprocessindustriesinasinglecomprehensivemeasurementEliminatefactorscontributingtoequipmentfailureImproveaccessibilityforcleaningandmaintainingequipmentUsepredictivemaintenanceasadiagnostictoolImplementmaintenanceaudits6TotalProductiveMaintenance(TPM)LearningObjectivesLearnamet個人學(xué)習(xí)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(fù)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)個人學(xué)習(xí)意義流程作業(yè)和保養(yǎng)最優(yōu)化7TotalProductWhat’sinItforMe?OptimizedprocessoperationsandmaintenanceAmethodtoreplacethetraditionalapproachofdetectingandcorrectingfaultyconditionsastheyoccurAproactivesystemwhichmonitorsandcorrectscausesAnoperationsstrategybasedonunderstandingthecauseandeffectsystemaffectingthemajorcontributorstoprocessperformance8TotalProductiveMaintenance(TPM)What’sinItforMe?Optimized全面生產(chǎn)維護(hù)(TPM)定義:一種用于監(jiān)控操作,設(shè)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)全面生產(chǎn)維護(hù)(TPM)定義:9TotalProductiTotalProductiveMaintenance(TPM)TPMDefinitionAcommonsenseapproachtomonitoroperations,maintainequipment,eliminateunscheduleddowntime,andimprovethelevelofcooperationbetweenOperationsandMaintenance.10TotalProductiveMaintenance(TPM)TotalProductiveMaintenance(TPM通過實施預(yù)防實現(xiàn)設(shè)備零故障和零缺陷;預(yù)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)異常快速反應(yīng)11TotalProductiveMaintenance(TPM)TPM通過實施預(yù)防實現(xiàn)設(shè)備零故障和零缺陷;11TotalPTPMAchievezeroequipmentbreakdownsandzerodefectsthroughpreventionEstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponse12TotalProductiveMaintenance(TPM)TPMAchievezeroequipmentbrea傳統(tǒng)的反應(yīng)式維護(hù)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(shè)備發(fā)生故障充當(dāng)救火員的角色;負(fù)責(zé)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(hù)活動一旦設(shè)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)傳統(tǒng)的反應(yīng)式維護(hù)維修部門–生產(chǎn)部門–TraditionalApproach

“Re-ActiveMaintenance”Maintenance–

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

“WEOPERATE”GenerallydoesnotperformanymaintenanceactivitiesContactsmaintenancewhenamachinebreakdownoccursInactiveduringmaintenanceactivities“Runit'tillitbreaks”14TotalProductiveMaintenance(TPM)TraditionalApproach

“Re-Activ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(shè)備進(jìn)行檢修的方法.在指定時間或在使用空檔間對設(shè)備實施檢修作業(yè)以防止設(shè)備發(fā)生故障.定期保養(yǎng)計劃 預(yù)測性保養(yǎng)是一種基于設(shè)備狀態(tài)的維護(hù)方法.根據(jù)可視信號或檢測技術(shù)的情況來實施保養(yǎng)以防止設(shè)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(yīng)油況分析預(yù)測性保養(yǎng)定期保養(yǎng)15TotalProductiveMaintenance(TPM)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(shè)備進(jìn)行檢修KeyDefinitions

PreventiveMaintenanceisatimeorusagebasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedondefinedtimeand/orusageintervalstopreventequipmentbreakdownsfromoccurring.PMSchedules

PredictiveMaintenanceisasituationbasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedonvisiblesignalsordiagnostictechniquestopreventequipmentbreakdownsfromoccurring.VibrationAnalysisLaserMeasuringUltrasoundGeneratorTestingThermographyOilAnalysisPredictiveMaintenancePreventiveMaintenance16TotalProductiveMaintenance(TPM)KeyDefinitions PreventiveMai現(xiàn)狀分析和團隊組織評估當(dāng)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(jìn)行優(yōu)先次序評估潛在TPM倡導(dǎo)者及團隊成員的實力挑選TPM倡導(dǎo)者及團隊成員建立初始的實施專門小組確定團隊目標(biāo)17TotalProductiveMaintenance(TPM)現(xiàn)狀分析和團隊組織評估當(dāng)前的操作條件:17TotalProPresentStateAnalysis

andTeamOrganizationAssessCurrentOperatingConditionsMachineutilization,productivity,etc.Maintenancerepaircosts(partsandlabor)PrioritizeorderofTPMeffortsAssesscapabilitiesofpotentialTPMChampionsandTeamMembersSelectTPMChampionandTeamMembersEstablishinitialkick-offworkshopEstablishteamgoal18TotalProductiveMaintenance(TPM)PresentStateAnalysis

andTea典型的設(shè)備評價指標(biāo)利用率:設(shè)備實際運轉(zhuǎn)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(biāo)準(zhǔn)產(chǎn)量的比率=(實際產(chǎn)量/小時)/(標(biāo)準(zhǔn)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)典型的設(shè)備評價指標(biāo)利用率:設(shè)備實際運轉(zhuǎn)時間與總的可利用時間TypicalOperationalProcessMeasurementsUtilization:Theratioofequipmentactualoperatingtimetothetotalavailableoperatingtime=ActualOperatingTime/AvailableTimeEfficiency:Theratioofactualproductproducedtoastandard=(ActualParts/Hour)/(StandardPart/Hour)Output:Measureofoutputoveraspecifiedtimeperiod=lbs/hr,pieces/hr20TotalProductiveMaintenance(TPM)TypicalOperationalProcessMe設(shè)備綜合利用率OEE設(shè)備綜合利用率（OEE）是衡量一臺設(shè)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)設(shè)備綜合利用率OEE設(shè)備綜合利用率（OEE）是衡量一臺設(shè)備按OverallEquipmentEffectivenessOverallEquipmentEffectiveness(OEE)isthemeasureofthepercentoftimeapieceofequipmentisproducingqualityproductatthedesignedrate.22TotalProductiveMaintenance(TPM)OverallEquipmentEffectivenesOEE分解:六大浪費故障及輕微故障使設(shè)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(shè)置時間浪費任何與設(shè)備調(diào)整,裝配,清潔相關(guān)的作業(yè).機器空轉(zhuǎn)浪費設(shè)備在運轉(zhuǎn)卻沒有用來生產(chǎn)產(chǎn)品所耗用的時間.

速度浪費由于設(shè)備或產(chǎn)品的異常造成設(shè)備以低于標(biāo)準(zhǔn)速度或所設(shè)定的速度運轉(zhuǎn).品質(zhì)原因浪費為確保設(shè)備產(chǎn)出品的品質(zhì)而采取相關(guān)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)OEE分解:六大浪費故障及輕微故障機器空轉(zhuǎn)浪費品質(zhì)原因浪費可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)OEEBreakdown:

TheSixBigLo六大浪費的識別練習(xí)25TotalProductiveMaintenance(TPM)六大浪費的識別練習(xí)25TotalProductiveMaSixBigLossesIdentificationExercise26TotalProductiveMaintenance(TPM)SixBigLossesIdentificationOEE的計算原理承載時間(LT)設(shè)備運轉(zhuǎn)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(wù)/非作業(yè)時間機器設(shè)置與調(diào)整速度損失機器空轉(zhuǎn)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)OEE的計算原理承載時間設(shè)備運轉(zhuǎn)總的可利用時間=40hCalculatingOEEElementsLoadingTime(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)CalculatingOEEElementsLoadin世界級的OEE性能水平承載時間(LT)同步計劃運轉(zhuǎn)時間及生產(chǎn)性防護(hù)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(wù)/非作業(yè)時間機器設(shè)置與調(diào)整速度損失機器空轉(zhuǎn)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)世界級的OEE性能水平承載時間同步計劃運轉(zhuǎn)時間及生產(chǎn)性防護(hù)時WorldClassOEEPerformanceLoadingTime(LT)OperationTimeandPMTimeisscheduledsynchronizingthetwoAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE90%x95%x99%QualityFactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrapOEE=85%isWorldClassPerformanceTheALisconsistentlykeptatorabove90%TheOLismaintainedatorabove95%TheQLisatorabove99%30TotalProductiveMaintenance(TPM)WorldClassOEEPerformanceLoa使設(shè)備恢復(fù)到可靠狀態(tài)消除故障開發(fā)PM維護(hù)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)使設(shè)備恢復(fù)到可靠狀態(tài)消除故障開發(fā)PM維護(hù)保養(yǎng)資料庫消除缺陷階ReturnEquipmenttoReliableConditionEliminateBreakdownsDevelopPMInformationDatabaseEliminateDefectsPHASEIPHASEIIPHASEIIIPHASEIVTPMPhases32TotalProductiveMaintenance(TPM)ReturnEquipmentEliminateDevel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(dāng)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(hù). 33TotalProductiveMaintenance(TPM)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SixTeamActivities1. Usesmallgroupactivitiestoimprovemachineuptimebyeliminatingthemajorsourcesofdowntime.StartupLosses BreakdownLossesMaterialandSchedulingLosses2. Involvethemachineoperatorsaswellasskilledtradesinbasicpreventativemaintenancesuchaslubrication,cleaning,andinspectionfordefects. 34TotalProductiveMaintenance(TPM)SixTeamActivities1. Usesmal六大團隊活動(續(xù)上頁)3. 使用諸如振動分析類的預(yù)測工具擯棄過去那種反應(yīng)式的維護(hù)模式4. 增強對設(shè)備的認(rèn)知和了解以提高生產(chǎn)效能,減少停工時間;5. 使供應(yīng)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(yīng),避免停機待料;6. 規(guī)劃人員配備以確保瓶頸設(shè)備處的滿員運作35TotalProductiveMaintenance(TPM)六大團隊活動(續(xù)上頁)3. 使用諸如振動分析類的預(yù)測工具擯棄SixTeamActivities(Cont.)3. Utilizepredictivetoolssuchasvibrationanalysistomovepastreactivetypemaintenance4. Increaseawarenessandknowledgeofequipmenttoimproveproductivityandreducedowntime5. WorkwithSupplyManagementandProductionControltoinsureaconstantflowofrawmaterialisavailabletoprecludeidling.6. Developmanningschedulesthatinsurethatbottleneckmachinesarefullystaffed36TotalProductiveMaintenance(TPM)SixTeamActivities(Cont.)3. TPM的益處提升操作員的參與感使設(shè)備恢復(fù)至更高的性能水平發(fā)現(xiàn)并消除早期的設(shè)備隱患減少總的制造成本減少浪費在保養(yǎng)設(shè)備方面樹立榮譽感促進(jìn)維護(hù)和生產(chǎn)部門之間的相互尊重與合作37TotalProductiveMaintenance(TPM)TPM的益處提升操作員的參與感37TotalProductBenefitsofTPMPromotesoperatorinvolvementRestoresequipmenttoahigherperformancelevelUncoverandeliminateprematureequipmentfailuresReducetotalmanufacturingcostsReduceswasteBuildsasenseofprideinmaintainingtheequipmentPromotescooperationandrespectbetweenmaintenanceandproduction38TotalProductiveMaintenance(TPM)BenefitsofTPMPromotesoperat職責(zé)范圍精益6Sigma團隊倡導(dǎo)者/發(fā)起人TPM團隊操作員現(xiàn)場主管維護(hù)人員39TotalProductiveMaintenance(TPM)職責(zé)范圍精益6Sigma團隊39TotalProductiAreasofResponsibilityLeanSixSigmaTeamChampion/SponsorTPMTeamOperatorSupervisorMaintenance40TotalProductiveMaintenance(TPM)AreasofResponsibilityLeanSi精益6Sigma團隊的任務(wù)確定一個TPM項目的需求收集有關(guān)維護(hù)成本,延遲(時延或操作延遲,設(shè)備利用率以及質(zhì)量問題的歷史數(shù)據(jù)與操作員進(jìn)行深入溝通以了解他們的期望41TotalProductiveMaintenance(TPM)精益6Sigma團隊的任務(wù)確定一個TPM項目的需求41TotLeanSixSigmaTeamRoleDeterminetheneedforaTPMProjectGatherhistoryofmaintenancecost,delay,machineavailability,andqualityproblemsInterviewOperatorstogettheirprospective42TotalProductiveMaintenance(TPM)LeanSixSigmaTeamRoleDeterm現(xiàn)場活動組成TPM團隊負(fù)責(zé)設(shè)備維護(hù)的人員操作員一線管理人員準(zhǔn)備必要的裝備幫助TPM團隊診斷異常協(xié)助跨功能培訓(xùn)收集整理故障標(biāo)牌的拷貝并生成工作明細(xì)表提供人力資源方面的支持精益6Sigma團隊的任務(wù)43TotalProductiveMaintenance(TPM)現(xiàn)場活動精益6Sigma團隊的任務(wù)43TotalProduLeanSixSigmaTeamRoleOnflooractivitiesAssembletheTPMTeamMaintenancepersonnelOperatorsFirstlinesupervisionProvidenecessaryequipmentHelpteamdiagnoseabnormalitiesAssistskilledtradesCollectcopiesofdefecttagsandgenerateaworklistProvidepeopleresources44TotalProductiveMaintenance(TPM)LeanSixSigmaTeamRoleOnflo倡導(dǎo)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(wù)并跟蹤其完成情況協(xié)助建立和引入正確的定期維護(hù)明細(xì)表協(xié)助維持改善結(jié)果評估設(shè)備綜合利用率OEE展示TPM的改善的成就45TotalProductiveMaintenance(TPM)倡導(dǎo)者/發(fā)起人的角色一旦完成現(xiàn)場工作,接下來將:45TotaChampion/SponsorRoleUponCompletionofOnFloorEventGenerateandtrackcompletionofworkordersAssistincreationandpostingofaccuratePeriodicMaintenanceListAssistinsustainingthegainsEvaluateOverallEquipmentEffectivenessDisplayTPMimprovements46TotalProductiveMaintenance(TPM)Champion/SponsorRoleUponComp現(xiàn)場主管的角色指導(dǎo)并推廣TPM概念監(jiān)控現(xiàn)場的設(shè)備管理,保養(yǎng)及機器清潔工作的進(jìn)行激發(fā)操作員的主人翁意識對操作員授權(quán)為TPM活動提供時間方面的準(zhǔn)備促進(jìn)生產(chǎn)與維護(hù)雙方的合作47TotalProductiveMaintenance(TPM)現(xiàn)場主管的角色指導(dǎo)并推廣TPM概念47TotalProduSupervisor’sRoleCoachandpromoteTPMConceptsMonitorongoinghousekeepingandmachinecleanlinessPromoteOperatorownershipEmpowerOperatorsProvidetimeforTPMactivitiesPromotecooperationbetweenProductionandMaintenance48TotalProductiveMaintenance(TPM)Supervisor’sRoleCoachandpro維護(hù)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(yīng)等預(yù)測工具;建立維護(hù)設(shè)備的保養(yǎng)記錄與操作員協(xié)同工作并提供技術(shù)支持執(zhí)行設(shè)備大修,綜合調(diào)試負(fù)責(zé)執(zhí)行一些特殊技能的任務(wù),風(fēng)險安全性高的作業(yè)促進(jìn)TPM49TotalProductiveMaintenance(TPM)維護(hù)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MaintenanceRole

“TheSpecializedCaretakers”PerformallplannedpreventativemaintenanceandtakecorrectiveactionasneededUsepredictivetoolssuchasvibrationanalysis,wearparticleanalysis,andthermographyDocumentequipmentmaintenancehistoryCooperatewithOperatorsandprovidetechnicalassistancePerformequipmentoverhaul,complexadjustmentsProvidespecialskilltasks,highsafetyrisktasksPromoteTPM50TotalProductiveMaintenance(TPM)MaintenanceRole

“TheSpeciali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(zhǔn)清單的項目進(jìn)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(shè)備異常根據(jù)需要協(xié)助維護(hù)人員進(jìn)行維修執(zhí)行基本的調(diào)試工作改善提案促進(jìn)TPM51TotalProductiveMaintenance(TPM)操作員角色

“一線管理者”清潔和缺陷檢查51TotalPrOperator’sRole

“TheFirstLineCaretaker”CleanandinspectfordefectsPerformbasiclubrication,multi-pointinspectionPerformPeriodicMaintenanceperapprovedListPerformroutinecleaningandhousekeepingasscheduledIdentifyequipmentdefectsastheyariseAssistMaintenancewithrepairsuponrequestPerformbasicadjustmentsSuggestimprovementsPromoteTPM52TotalProductiveMaintenance(TPM)Operator’sRole

“TheFirstLin全面生產(chǎn)維護(hù)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(biāo)示3.建立操作員及維護(hù)人員的定期檢測的PM計劃4. 指導(dǎo)操作員使用正確的保養(yǎng)方法5. 指導(dǎo)維護(hù)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)全面生產(chǎn)維護(hù)的七大步驟1.完成初始的機器清潔和檢查53The7Stepsof

TotalProductiveMaintenance1. Performinitialmachinecleaningandinspection2. Identifyandtagmachinedefectsandleaks3.DevelopOperatorandMaintenancePM’s4. InstructOperatorsinproperPMtechniques5. InstructMaintenanceStaffinproperPMtechniques6. Implement5SHousekeepingandOrganization7. MonitorOEEandencouragecooperation54TotalProductiveMaintenance(TPM)The7Stepsof

TotalProductiTPM安全常識遵守/使用停工現(xiàn)場標(biāo)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(hù)目鏡防塵口罩耳塞55TotalProductiveMaintenance(TPM)TPM安全常識遵守/使用55TotalProductivTPMSafetyHabitsFollow/UseLockoutTagoutProcedureProperLiftingTechniquesElectricalSafetyGuidelinesPersonalProtectiveEquipmentGlovesSafetyShoesGogglesRespiratorsHearingProtection56TotalProductiveMaintenance(TPM)TPMSafetyHabitsFollow/Use56TTPM步驟1初始的機器清潔和檢查目的:識別需修理處并標(biāo)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(biāo)示并記錄57TotalProductiveMaintenance(TPM)TPM步驟1初始的機器清潔和檢查57TotalProduTPMStep1InitialMachineInspectionPurpose:ToIdentifyneededrepairsandtagdefectsExecution:Cleanmachinethoroughly–donebyallteammembersTagandrecordallrepairsneededinaprojectnotebook58TotalProductiveMaintenance(TPM)TPMStep1InitialMachineInspTPM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)TPM步驟1

“現(xiàn)場活動”徹底的清潔工作包括:59TotaTPMStep1

“OnFloorActivities”AThoroughCleaningIncludes:RemovingallchipsandotherdebrisThoroughDegreasingCompressedairforcontrolsChangingfilters,lubricants,etc.LubricatingmovingpartsandjointsRemovingunnecessarytooling,hardware,supplies,etc.“Youhavetogetyourhandsdirty!”60TotalProductiveMaintenance(TPM)TPMStep1

“OnFloorActivitieTPM步驟1

“現(xiàn)場活動”維修項標(biāo)示色碼

標(biāo)簽上須標(biāo)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(lán)色61TotalProductiveMaintenance(TPM)TPM步驟1

“現(xiàn)場活動”維修項標(biāo)示色碼61TotalPTPMStep1

“OnFloorActivities”RepairTagColorCodes

InformationNeededonTagsAssetnumberofmachineLocationandrelativepositionofdefectonmachineNameoforiginatoranddateOilLeaks-OrangeCoolantLeaks-GreenAirLeaks-YellowMachineDefects-PinkElectricalProblems-Blue62TotalProductiveMaintenance(TPM)TPMStep1

“OnFloorActivitie關(guān)注TPM清潔效果

降低停機時間>70%之前–砂粒及碎屑很嚴(yán)重?zé)o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(fù)至設(shè)計速度且保持品質(zhì)63TotalProductiveMaintenance(TPM)關(guān)注TPM清潔效果

降低停機時間>70%之前–砂粒及碎FocusedTPMCleaningEffort

ReducedDowntimeby>70%Before–SevereGritandChipsOutofadjustmentsRunningatreducedspeedsConstantbreakdownsAfter–Cross-functionalEffortReplacedbrokenandmissingpartsCorrectedtheadjustmentReturnedtodesignedspeedwithoutincurringscrap64TotalProductiveMaintenance(TPM)FocusedTPMCleaningEffort

RTPM步驟2修復(fù)機器的缺漏目的:修復(fù)在步驟1中找到的缺漏項目注意事項:倡導(dǎo)者/發(fā)起人需確保標(biāo)示出的問題得到修復(fù)實際的修復(fù)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)TPM步驟2修復(fù)機器的缺漏65TotalProductiTPMStep2RepairmachinedefectsandleaksPurpose:TorepairitemsfoundinStep1Considerations:Champion/SponsorinsurestaggedproblemsarerepairedActualrepairsdonothavetobedonebyteammembersProductionSupervisorhastomakemachineavailable66TotalProductiveMaintenance(TPM)TPMStep2RepairmachinedefecTPM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)TPM步驟2消除故障因素67TotalProductivTPMStep2Eliminatefactorscontributingtofailure:Secureandtightenallfasteners,fittings,boltsandscrewsReplaceanymissingpartsReplaceanydamaged,wornorwrongsizepartsResolveallcausesofleaks,spillage,sprayandsplatterImproveaccessibilityinordertoaccomplish:Cleaning LubricatingAdjustingChecking/inspecting68TotalProductiveMaintenance(TPM)TPMStep2EliminatefactorscoTPM步驟3建立操作員和維護(hù)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(wù)任務(wù)執(zhí)行的頻率(例如每天,每周等)69TotalProductiveMaintenance(TPM)TPM步驟3建立操作員和維護(hù)人員合作的PM計劃69TotaTPMStep3DevelopOperatorPM’sandMaintenancePM’sPurpose:ToinsureadequatepreventativemaintenancechecklistsarepostedConsiderations:TPMProjectTeamtodevelopPM’sWhoistoperformtasksFrequencyoftasks(i.e.,daily,weekly,etc.)70TotalProductiveMaintenance(TPM)TPMStep3DevelopOperatorPM’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(zhǔn)備周期保養(yǎng),遵循5S規(guī)程注意事項:操作員負(fù)責(zé)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)TPM步驟4由操作員執(zhí)行的PM作業(yè)71TotalProdTPMStep4PMactivityperformedbytheOperatorPurpose:Todetectearlyproblems,providetheserviceinterval,andinsure5SprocedureisfollowedConsiderations:OperatorisresponsibletoperformPM’sasdocumentedProductionSupervisortoinsurePM’sareeffective72TotalProductiveMaintenance(TPM)TPMStep4PMactivityperformeTPMTPM使操作員更加獨立地自我管理和控制;操作員時時關(guān)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(shè)備整體狀況73TotalProductiveMaintenance(TPM)TPMTPM使操作員更加獨立地自我管理和控制;73TotalTPMTPMmakestheoperatormoreindependentTheoperatorseesthesmallproblemsnowwiththepossibilityof: QuicklynotingpotentialproblemsCorrectingthecurrentsituationRecognizingnormalconditionsMaintainingthemachineingoodoverallcondition74TotalProductiveMaintenance(TPM)TPMTPMmakestheoperatormore自主維護(hù)管理指的是操作員參與自己所操作的設(shè)備的維護(hù)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(hù)/生產(chǎn)作業(yè)的規(guī)定明確操作員如何進(jìn)行日常檢測進(jìn)行基本的操作,維護(hù)及故障檢測的培訓(xùn)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)自主維護(hù)管理指的是操作員參與自己所操作的設(shè)備的維護(hù)作業(yè)75TAutonomousMaintenanceReferstoactivitiesinvolvingoperatorsinthemaintenanceoftheirownequipmentHowtomaketheoperatormoreindependent:MakedocumentationavailableDefinemaintenance/manufacturingactivitiesShowoperatorhowtoperformdailychecksTraininbasicoperation,maintenance,anddefectdetectionMakedailyactivitiesvisibleClearlyidentifyitemstosupervise76TotalProductiveMaintenance(TPM)AutonomousMaintenanceReferst落實自主維護(hù)管理確定過程實施中的關(guān)鍵機器及設(shè)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(biāo)準(zhǔn)就設(shè)備的保養(yǎng)需求對操作員進(jìn)行培訓(xùn)貫徹實施一個綜合性的維護(hù)系統(tǒng)對保養(yǎng)效果進(jìn)行定期審查77TotalProductiveMaintenance(TPM)落實自主維護(hù)管理確定過程實施中的關(guān)鍵機器及設(shè)備77TotalAutonomousMaintenanceImplementationIdentifyprocesscriticalmachineryandequipmentPerforminitialcleaningResolvesourcesofdirtandcontaminationCreatecleaningandlubricationstandardsTrainoperatorsonequipmentmaintenancerequirementsImplementacomprehensivemaintenancesystemEstablishperiodicauditsofmaintenanceeffectiveness78TotalProductiveMaintenance(TPM)AutonomousMaintenanceImpleme為什么清潔?不恰當(dāng)?shù)那鍧嵥鶐淼呢?fù)面影響:故障產(chǎn)品缺陷加快設(shè)備磨損產(chǎn)量降低設(shè)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(dǎo)致加快磨損79TotalProductiveMaintenance(TPM)為什么清潔?不恰當(dāng)?shù)那鍧嵥鶐淼呢?fù)面影響:79TotalPWhyClean?AdverseeffectsofinadequatecleaningFailureProductdefectsAccelerateddeteriorationThroughputlossEquipmentdeteriorationNormaldeterioration:occursdespitecorrectuseAccelerateddeterioration:quickerdeteriorationoccurringduetomisuseinoperationandneglectofmaintenance80TotalProductiveMaintenance(TPM)WhyClean?Adverseeffectsofi清潔可作為磨損檢查清潔可減緩磨損速度接觸設(shè)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)清潔可作為磨損檢查清潔可減緩磨損速度81TotalProdCleaningasDetectionofDeteriorationCleaningreducesaccelerateddeteriorationPhysicalcontactwithequipmentexposesabnormaloperationconditionsPreventiveactiontakenextendsusefullifeandavoidsbreakdowns82TotalProductiveMaintenance(TPM)CleaningasDetectionofDeter常見的設(shè)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(hù)裝置損壞或不見83TotalProductiveMaintenance(TPM)常見的設(shè)備缺陷斷線83TotalProductiveMTypicalDefectsFoundBrokenflexWornhosesOilleaksAirLeaksCoolantleaksBrokenBracketsFrayedwiresUnnecessaryandobsoletetoolingDamagedormissingguards84TotalProductiveMaintenance(TPM)TypicalDefectsFoundBrokenfl設(shè)備故障專家估計與移動裝置相關(guān)的機器故障有60%是由于缺乏或不適當(dāng)?shù)臐櫥瑢?dǎo)致的;建立設(shè)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(jié)報告包括用于定期回顧之用的會議議程報告85TotalProductiveMaintenance(TPM)設(shè)備故障專家估計與移動裝置相關(guān)的機器故障有60%是由于缺乏或EquipmentFailuresExpertsestimatethat60%ofmachinebreakdownsassociatedwithmovingpartsareduetolackoforimproperlubricationpractices.EstablishanequipmentfailuredatabaseGatherandmanagefailureinformationAnalyzefortrendsandpatternsDevelopandissueperiodicsummaryreportsIncludereportsasameetingagendaforregularreview86TotalProductiveMaintenance(TPM)EquipmentFailuresExpertsestiTPM步驟4(續(xù)）目視管理張貼設(shè)備潤滑工作示意圖標(biāo)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(biāo)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)TPM步驟4(續(xù)）目視管理87TotalProductTPMStep4（Con.)VisualsControlsLubricationplacardsinplaceUpperandlowersightglassesinplaceAllair,water,gas,andcoolantlinesarelabeledOEEpostedYTDMaintenancecostsposted5SAuditScoresposted88TotalProductiveMaintenance(TPM)TPMStep4（Con.)VisualsContTPM步驟5由維護(hù)人員執(zhí)行的PM作業(yè)目的:預(yù)防機器故障在發(fā)生故障之前解決注意事項:PM作