TPM全面生產(chǎn)維護(hù)課件

2022/12/10TPM全面生產(chǎn)維護(hù)2022/12/10TPM全面生產(chǎn)維護(hù)1TotalProductiveMaintenance(TPM)TPMTPMTeamOrganizationOverallEquipmentEffectivenessTPMPhasesRD011202TotalProductiveMaintenance(2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(xiàng)目焦點(diǎn)和重要指標(biāo)完成PDF測(cè)量繪制業(yè)務(wù)流程圖繪制價(jià)值流程圖制定數(shù)據(jù)收集計(jì)劃測(cè)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(yàn)證關(guān)鍵因子評(píng)枯每個(gè)關(guān)鍵因子對(duì)結(jié)果的影響量化機(jī)會(huì)根本原因排序?qū)ふ腋驹蜥槍?duì)關(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(shí)行方案控制過程變革和控制制定控制計(jì)劃計(jì)算最終財(cái)務(wù)過程指標(biāo)項(xiàng)目過渡給未來項(xiàng)目管理者項(xiàng)目鑒別轉(zhuǎn)化機(jī)會(huì)測(cè)量定義項(xiàng)目編號(hào)工具項(xiàng)目定義表凈現(xiàn)值分析內(nèi)部回報(bào)率分析折算現(xiàn)金流分析PIP管理過程RACIQuad表過程圖價(jià)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(yùn)行圖控制圖量具R&RCp&Cpk供應(yīng)鏈加速器分析多變動(dòng)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(yàn)力場(chǎng)分析圖樹狀圖甘特圖查檢表運(yùn)行圖柱狀圖散布圖控制圖柏拉圖互動(dòng)回顧愚巧法Revised1-12-023精益6

過程改善流程分析控制改進(jìn)定義測(cè)量分析改進(jìn)控制測(cè)3LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-024LeanSixSigma

ImprovementPr4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(gè)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(cè)性保養(yǎng)作為一種檢測(cè)工具;實(shí)施維護(hù)審查5課程目的學(xué)習(xí)一種方法以便:55LearningObjectivesLearnamethodto:IntegrateoperationalproductivityfactorsapplicableinprocessindustriesinasinglecomprehensivemeasurementEliminatefactorscontributingtoequipmentfailureImproveaccessibilityforcleaningandmaintainingequipmentUsepredictivemaintenanceasadiagnostictoolImplementmaintenanceaudits6LearningObjectivesLearnamet6個(gè)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(shí)檢測(cè)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(duì)影響過程性能的主要因素其因果系統(tǒng)的理解工作策略;7個(gè)人學(xué)習(xí)意義流程作業(yè)和保養(yǎng)最優(yōu)化77What’sinItforMe?OptimizedprocessoperationsandmaintenanceAmethodtoreplacethetraditionalapproachofdetectingandcorrectingfaultyconditionsastheyoccurAproactivesystemwhichmonitorsandcorrectscausesAnoperationsstrategybasedonunderstandingthecauseandeffectsystemaffectingthemajorcontributorstoprocessperformance8What’sinItforMe?Optimized8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(jì)劃外停機(jī),和提高作業(yè)與保養(yǎng)協(xié)調(diào)程度的常識(shí)性方法。9全面生產(chǎn)維護(hù)(TPM)定義:99TotalProductiveMaintenance(TPM)TPMDefinitionAcommonsenseapproachtomonitoroperations,maintainequipment,eliminateunscheduleddowntime,andimprovethelevelofcooperationbetweenOperationsandMaintenance.10TotalProductiveMaintenance(10TPM通過實(shí)施預(yù)防實(shí)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?？焖俜磻?yīng)11TPM通過實(shí)施預(yù)防實(shí)現(xiàn)設(shè)備零故障和零缺陷;1111TPMAchievezeroequipmentbreakdownsandzerodefectsthroughpreventionEstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponse12TPMAchievezeroequipmentbrea12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(gòu)和保管所有的工具,備件等物資;實(shí)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(dòng)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13傳統(tǒng)的反應(yīng)式維護(hù)維修部門–生產(chǎn)部門–13TraditionalApproach

“Re-ActiveMaintenance”Maintenance–

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

“WEOPERATE”GenerallydoesnotperformanymaintenanceactivitiesContactsmaintenancewhenamachinebreakdownoccursInactiveduringmaintenanceactivities“Runit'tillitbreaks”14TraditionalApproach

“Re-Activ14主要概念 定期保養(yǎng)是一種基于時(shí)間長(zhǎng)短或使用狀況對(duì)設(shè)備進(jìn)行檢修的方法.在指定時(shí)間或在使用空檔間對(duì)設(shè)備實(shí)施檢修作業(yè)以防止設(shè)備發(fā)生故障.定期保養(yǎng)計(jì)劃 預(yù)測(cè)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(hào)或檢測(cè)技術(shù)的情況來實(shí)施保養(yǎng)以防止設(shè)備發(fā)生故障.振動(dòng)分析激光探測(cè)超聲波檢測(cè)發(fā)電機(jī)測(cè)試熱感應(yīng)油況分析預(yù)測(cè)性保養(yǎng)定期保養(yǎng)15主要概念 定期保養(yǎng)是一種基于時(shí)間長(zhǎng)短或使用狀況對(duì)設(shè)備進(jìn)行檢修15KeyDefinitions PreventiveMaintenanceisatimeorusagebasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedondefinedtimeand/orusageintervalstopreventequipmentbreakdownsfromoccurring.PMSchedules PredictiveMaintenanceisasituationbasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedonvisiblesignalsordiagnostictechniquestopreventequipmentbreakdownsfromoccurring.VibrationAnalysisLaserMeasuringUltrasoundGeneratorTestingThermographyOilAnalysisPredictiveMaintenancePreventiveMaintenance16KeyDefinitions PreventiveMai16現(xiàn)狀分析和團(tuán)隊(duì)組織評(píng)估當(dāng)前的操作條件:機(jī)器利用率,生產(chǎn)率等;維修費(fèi)用(配件和人工)對(duì)實(shí)現(xiàn)TPM的各項(xiàng)工作進(jìn)行優(yōu)先次序評(píng)估潛在TPM倡導(dǎo)者及團(tuán)隊(duì)成員的實(shí)力挑選TPM倡導(dǎo)者及團(tuán)隊(duì)成員建立初始的實(shí)施專門小組確定團(tuán)隊(duì)目標(biāo)17現(xiàn)狀分析和團(tuán)隊(duì)組織評(píng)估當(dāng)前的操作條件:1717PresentStateAnalysis

andTeamOrganizationAssessCurrentOperatingConditionsMachineutilization,productivity,etc.Maintenancerepaircosts(partsandlabor)PrioritizeorderofTPMeffortsAssesscapabilitiesofpotentialTPMChampionsandTeamMembersSelectTPMChampionandTeamMembersEstablishinitialkick-offworkshopEstablishteamgoal18PresentStateAnalysis

andTea18典型的設(shè)備評(píng)價(jià)指標(biāo)利用率:設(shè)備實(shí)際運(yùn)轉(zhuǎn)時(shí)間與總的可利用時(shí)間的比率;=實(shí)際運(yùn)行時(shí)間/可運(yùn)行時(shí)間效率:實(shí)際產(chǎn)量與標(biāo)準(zhǔn)產(chǎn)量的比率=(實(shí)際產(chǎn)量/小時(shí))/(標(biāo)準(zhǔn)產(chǎn)量/小時(shí))產(chǎn)出:用一特定時(shí)間段的產(chǎn)量來衡量=

磅/小時(shí),件數(shù)/小時(shí)19典型的設(shè)備評(píng)價(jià)指標(biāo)利用率:設(shè)備實(shí)際運(yùn)轉(zhuǎn)時(shí)間與總的可利用時(shí)間19TypicalOperationalProcessMeasurementsUtilization:Theratioofequipmentactualoperatingtimetothetotalavailableoperatingtime=ActualOperatingTime/AvailableTimeEfficiency:Theratioofactualproductproducedtoastandard=(ActualParts/Hour)/(StandardPart/Hour)Output:Measureofoutputoveraspecifiedtimeperiod=lbs/hr,pieces/hr20TypicalOperationalProcessMe20設(shè)備綜合利用率OEE設(shè)備綜合利用率（OEE）是衡量一臺(tái)設(shè)備按計(jì)劃速度生產(chǎn)出合格產(chǎn)品的時(shí)間占全部時(shí)間的百分比.21設(shè)備綜合利用率OEE設(shè)備綜合利用率（OEE）是衡量一臺(tái)設(shè)備按21OverallEquipmentEffectivenessOverallEquipmentEffectiveness(OEE)isthemeasureofthepercentoftimeapieceofequipmentisproducingqualityproductatthedesignedrate.22OverallEquipmentEffectivenes22OEE分解:六大浪費(fèi)故障及輕微故障使設(shè)備中斷運(yùn)行的時(shí)間超過10分鐘的故障或者中斷時(shí)間少于10分鐘的輕微故障.設(shè)置時(shí)間浪費(fèi)任何與設(shè)備調(diào)整,裝配,清潔相關(guān)的作業(yè).機(jī)器空轉(zhuǎn)浪費(fèi)設(shè)備在運(yùn)轉(zhuǎn)卻沒有用來生產(chǎn)產(chǎn)品所耗用的時(shí)間.

速度浪費(fèi)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(yùn)轉(zhuǎn).品質(zhì)原因浪費(fèi)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(fèi)用于返修產(chǎn)品或生產(chǎn)出報(bào)廢產(chǎn)品所耗用的時(shí)間.可用水平(AL)運(yùn)行水平(OL)質(zhì)量水平(QL)23OEE分解:六大浪費(fèi)故障及輕微故障機(jī)器空轉(zhuǎn)浪費(fèi)品質(zhì)原因浪費(fèi)可23OEEBreakdown:

TheSixBigLossesBreakdownsand

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

SpeedLossesEquipmentoperatingatlessthanstandardordesignspeedduetoequipment/productabnormalityQualityFactorsActivitiesrelatedtoensuringthequalityoftheproductproducedontheequipment(in-processchecks).

ReworkLossesThetimetakentore-processproductortimetaketoproduceun-usableproduct.AvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)24OEEBreakdown:

TheSixBigLo24六大浪費(fèi)的識(shí)別練習(xí)25六大浪費(fèi)的識(shí)別練習(xí)2525SixBigLossesIdentificationExercise26SixBigLossesIdentification26OEE的計(jì)算原理承載時(shí)間(LT)設(shè)備運(yùn)轉(zhuǎn)總的可利用時(shí)間=40hrs可用水平(AL)運(yùn)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(jī)器故障及輕微故障,行政事務(wù)/非作業(yè)時(shí)間機(jī)器設(shè)置與調(diào)整速度損失機(jī)器空轉(zhuǎn)返工及報(bào)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=21.1hrs27OEE的計(jì)算原理承載時(shí)間設(shè)備運(yùn)轉(zhuǎn)總的可利用時(shí)間=40h27CalculatingOEEElementsLoadingTime(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=21.1hrs28CalculatingOEEElementsLoadin28世界級(jí)的OEE性能水平承載時(shí)間(LT)同步計(jì)劃運(yùn)轉(zhuǎn)時(shí)間及生產(chǎn)性防護(hù)時(shí)間可用水平(AL)運(yùn)行水平(OL)質(zhì)量水平(QL)OEE90%x95%x99%質(zhì)量原因機(jī)器故障及輕微故障,行政事務(wù)/非作業(yè)時(shí)間機(jī)器設(shè)置與調(diào)整速度損失機(jī)器空轉(zhuǎn)返工及報(bào)廢OEE=85%是世界級(jí)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%29世界級(jí)的OEE性能水平承載時(shí)間同步計(jì)劃運(yùn)轉(zhuǎn)時(shí)間及生產(chǎn)性防護(hù)時(shí)29WorldClassOEEPerformanceLoadingTime(LT)OperationTimeandPMTimeisscheduledsynchronizingthetwoAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE90%x95%x99%QualityFactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrapOEE=85%isWorldClassPerformanceTheALisconsistentlykeptatorabove90%TheOLismaintainedatorabove95%TheQLisatorabove99%30WorldClassOEEPerformanceLoa30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(kù)消除缺陷階段I階段II階段III階段IVTPM階段31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(kù)消除缺陷階31ReturnEquipmenttoReliableConditionEliminateBreakdownsDevelopPMInformationDatabaseEliminateDefectsPHASEIPHASEIIPHASEIIIPHASEIVTPMPhases32ReturnEquipmentEliminateDevel32六大團(tuán)隊(duì)活動(dòng)1. 通過小規(guī)模的小組活動(dòng)來提高機(jī)器的正常運(yùn)行時(shí)間,消除造成停工的主要根源:機(jī)器的啟動(dòng)損失 機(jī)器的故障損失待料損失和生產(chǎn)安排不當(dāng)帶來的停機(jī)損失2. 使操作員熟練地參與如潤(rùn)滑,清潔,故障檢驗(yàn)等基本的保養(yǎng)維護(hù). 33六大團(tuán)隊(duì)活動(dòng)1. 通過小規(guī)模的小組活動(dòng)來提高機(jī)器的正常運(yùn)行時(shí)33SixTeamActivities1. Usesmallgroupactivitiestoimprovemachineuptimebyeliminatingthemajorsourcesofdowntime.StartupLosses BreakdownLossesMaterialandSchedulingLosses2. Involvethemachineoperatorsaswellasskilledtradesinbasicpreventativemaintenancesuchaslubrication,cleaning,andinspectionfordefects. 34SixTeamActivities1. Usesmal34六大團(tuán)隊(duì)活動(dòng)(續(xù)上頁(yè))3. 使用諸如振動(dòng)分析類的預(yù)測(cè)工具擯棄過去那種反應(yīng)式的維護(hù)模式4. 增強(qiáng)對(duì)設(shè)備的認(rèn)知和了解以提高生產(chǎn)效能,減少停工時(shí)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(jī)待料;6. 規(guī)劃人員配備以確保瓶頸設(shè)備處的滿員運(yùn)作35六大團(tuán)隊(duì)活動(dòng)(續(xù)上頁(yè))3. 使用諸如振動(dòng)分析類的預(yù)測(cè)工具擯棄35SixTeamActivities(Cont.)3. Utilizepredictivetoolssuchasvibrationanalysistomovepastreactivetypemaintenance4. Increaseawarenessandknowledgeofequipmenttoimproveproductivityandreducedowntime5. WorkwithSupplyManagementandProductionControltoinsureaconstantflowofrawmaterialisavailabletoprecludeidling.6. Developmanningschedulesthatinsurethatbottleneckmachinesarefullystaffed36SixTeamActivities(Cont.)3. 36TPM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(fèi)在保養(yǎng)設(shè)備方面樹立榮譽(yù)感促進(jìn)維護(hù)和生產(chǎn)部門之間的相互尊重與合作37TPM的益處提升操作員的參與感3737BenefitsofTPMPromotesoperatorinvolvementRestoresequipmenttoahigherperformancelevelUncoverandeliminateprematureequipmentfailuresReducetotalmanufacturingcostsReduceswasteBuildsasenseofprideinmaintainingtheequipmentPromotescooperationandrespectbetweenmaintenanceandproduction38BenefitsofTPMPromotesoperat38職責(zé)范圍精益6Sigma團(tuán)隊(duì)倡導(dǎo)者/發(fā)起人TPM團(tuán)隊(duì)操作員現(xiàn)場(chǎng)主管維護(hù)人員39職責(zé)范圍精益6Sigma團(tuán)隊(duì)3939AreasofResponsibilityLeanSixSigmaTeamChampion/SponsorTPMTeamOperatorSupervisorMaintenance40AreasofResponsibilityLeanSi40精益6Sigma團(tuán)隊(duì)的任務(wù)確定一個(gè)TPM項(xiàng)目的需求收集有關(guān)維護(hù)成本,延遲(時(shí)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41精益6Sigma團(tuán)隊(duì)的任務(wù)確定一個(gè)TPM項(xiàng)目的需求4141LeanSixSigmaTeamRoleDeterminetheneedforaTPMProjectGatherhistoryofmaintenancecost,delay,machineavailability,andqualityproblemsInterviewOperatorstogettheirprospective42LeanSixSigmaTeamRoleDeterm42現(xiàn)場(chǎng)活動(dòng)組成TPM團(tuán)隊(duì)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(tuán)隊(duì)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(tuán)隊(duì)的任務(wù)43現(xiàn)場(chǎng)活動(dòng)精益6Sigma團(tuán)隊(duì)的任務(wù)4343LeanSixSigmaTeamRoleOnflooractivitiesAssembletheTPMTeamMaintenancepersonnelOperatorsFirstlinesupervisionProvidenecessaryequipmentHelpteamdiagnoseabnormalitiesAssistskilledtradesCollectcopiesofdefecttagsandgenerateaworklistProvidepeopleresources44LeanSixSigmaTeamRoleOnflo44倡導(dǎo)者/發(fā)起人的角色一旦完成現(xiàn)場(chǎng)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(píng)估設(shè)備綜合利用率OEE展示TPM的改善的成就45倡導(dǎo)者/發(fā)起人的角色一旦完成現(xiàn)場(chǎng)工作,接下來將:4545Champion/SponsorRoleUponCompletionofOnFloorEventGenerateandtrackcompletionofworkordersAssistincreationandpostingofaccuratePeriodicMaintenanceListAssistinsustainingthegainsEvaluateOverallEquipmentEffectivenessDisplayTPMimprovements46Champion/SponsorRoleUponComp46現(xiàn)場(chǎng)主管的角色指導(dǎo)并推廣TPM概念監(jiān)控現(xiàn)場(chǎng)的設(shè)備管理,保養(yǎng)及機(jī)器清潔工作的進(jìn)行激發(fā)操作員的主人翁意識(shí)對(duì)操作員授權(quán)為TPM活動(dòng)提供時(shí)間方面的準(zhǔn)備促進(jìn)生產(chǎn)與維護(hù)雙方的合作47現(xiàn)場(chǎng)主管的角色指導(dǎo)并推廣TPM概念4747Supervisor’sRoleCoachandpromoteTPMConceptsMonitorongoinghousekeepingandmachinecleanlinessPromoteOperatorownershipEmpowerOperatorsProvidetimeforTPMactivitiesPromotecooperationbetweenProductionandMaintenance48Supervisor’sRoleCoachandpro48維護(hù)人員的角色

“專業(yè)的管理者”有計(jì)劃的實(shí)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(dòng)分析,磨損度分析,熱感應(yīng)等預(yù)測(cè)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(xiǎn)安全性高的作業(yè)促進(jìn)TPM49維護(hù)人員的角色

“專業(yè)的管理者”有計(jì)劃的實(shí)施所有的定期保養(yǎng)并49MaintenanceRole

“TheSpecializedCaretakers”PerformallplannedpreventativemaintenanceandtakecorrectiveactionasneededUsepredictivetoolssuchasvibrationanalysis,wearparticleanalysis,andthermographyDocumentequipmentmaintenancehistoryCooperatewithOperatorsandprovidetechnicalassistancePerformequipmentoverhaul,complexadjustmentsProvidespecialskilltasks,highsafetyrisktasksPromoteTPM50MaintenanceRole

“TheSpeciali50操作員角色

“一線管理者”清潔和缺陷檢查執(zhí)行基本的潤(rùn)滑,多點(diǎn)檢測(cè)的工作按照核準(zhǔn)清單的項(xiàng)目進(jìn)行定期保養(yǎng)按計(jì)劃執(zhí)行日常清潔和整理識(shí)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)TPM51操作員角色

“一線管理者”清潔和缺陷檢查5151Operator’sRole

“TheFirstLineCaretaker”CleanandinspectfordefectsPerformbasiclubrication,multi-pointinspectionPerformPeriodicMaintenanceperapprovedListPerformroutinecleaningandhousekeepingasscheduledIdentifyequipmentdefectsastheyariseAssistMaintenancewithrepairsuponrequestPerformbasicadjustmentsSuggestimprovementsPromoteTPM52Operator’sRole

“TheFirstLin52全面生產(chǎn)維護(hù)的七大步驟1.完成初始的機(jī)器清潔和檢查2.識(shí)別機(jī)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(cè)的PM計(jì)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(chǎng)5S管理和組織活動(dòng)7. 監(jiān)控OEE并鼓勵(lì)大家合作53全面生產(chǎn)維護(hù)的七大步驟1.完成初始的機(jī)器清潔和檢查5353The7Stepsof

TotalProductiveMaintenance1. Performinitialmachinecleaningandinspection2. Identifyandtagmachinedefectsandleaks3.DevelopOperatorandMaintenancePM’s4. InstructOperatorsinproperPMtechniques5. InstructMaintenanceStaffinproperPMtechniques6. Implement5SHousekeepingandOrganization7. MonitorOEEandencouragecooperation54The7Stepsof

TotalProducti54TPM安全常識(shí)遵守/使用停工現(xiàn)場(chǎng)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55TPM安全常識(shí)遵守/使用5555TPMSafetyHabitsFollow/UseLockoutTagoutProcedureProperLiftingTechniquesElectricalSafetyGuidelinesPersonalProtectiveEquipmentGlovesSafetyShoesGogglesRespiratorsHearingProtection56TPMSafetyHabitsFollow/Use5656TPM步驟1初始的機(jī)器清潔和檢查目的:識(shí)別需修理處并標(biāo)示缺陷執(zhí)行:徹底清潔機(jī)器團(tuán)隊(duì)所有成員參與并將所有需要維修的項(xiàng)目標(biāo)示并記錄57TPM步驟1初始的機(jī)器清潔和檢查5757TPMStep1InitialMachineInspectionPurpose:ToIdentifyneededrepairsandtagdefectsExecution:Cleanmachinethoroughly–donebyallteammembersTagandrecordallrepairsneededinaprojectnotebook58TPMStep1InitialMachineInsp58TPM步驟1

“現(xiàn)場(chǎng)活動(dòng)”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(rùn)滑劑等潤(rùn)滑移動(dòng)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(huì)臟兮兮的!”59TPM步驟1

“現(xiàn)場(chǎng)活動(dòng)”徹底的清潔工作包括:5959TPMStep1

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

“OnFloorActivitie60TPM步驟1

“現(xiàn)場(chǎng)活動(dòng)”維修項(xiàng)標(biāo)示色碼

標(biāo)簽上須標(biāo)示的信息:機(jī)器的資產(chǎn)編號(hào)機(jī)器位置及故障位置投入使用的日期及使用人機(jī)油泄漏—橙色冷卻液泄漏—綠色空氣泄漏–黃色機(jī)器故障–粉紅色電氣問題--藍(lán)色61TPM步驟1

“現(xiàn)場(chǎng)活動(dòng)”維修項(xiàng)標(biāo)示色碼6161TPMStep1

“OnFloorActivities”RepairTagColorCodes

InformationNeededonTagsAssetnumberofmachineLocationandrelativepositionofdefectonmachineNameoforiginatoranddateOilLeaks-OrangeCoolantLeaks-GreenAirLeaks-YellowMachineDefects-PinkElectricalProblems-Blue62TPMStep1

“OnFloorActivitie62關(guān)注TPM清潔效果

降低停機(jī)時(shí)間>70%之前–砂粒及碎屑很嚴(yán)重?zé)o法調(diào)試運(yùn)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(jì)速度且保持品質(zhì)63關(guān)注TPM清潔效果

降低停機(jī)時(shí)間>70%之前–砂粒及碎63FocusedTPMCleaningEffort

ReducedDowntimeby>70%Before–SevereGritandChipsOutofadjustmentsRunningatreducedspeedsConstantbreakdownsAfter–Cross-functionalEffortReplacedbrokenandmissingpartsCorrectedtheadjustmentReturnedtodesignedspeedwithoutincurringscrap64FocusedTPMCleaningEffort

R64TPM步驟2修復(fù)機(jī)器的缺漏目的:修復(fù)在步驟1中找到的缺漏項(xiàng)目注意事項(xiàng):倡導(dǎo)者/發(fā)起人需確保標(biāo)示出的問題得到修復(fù)實(shí)際的修復(fù)工作不必一定由團(tuán)隊(duì)成員來做;生產(chǎn)主管須確保機(jī)器能夠使用65TPM步驟2修復(fù)機(jī)器的缺漏6565TPMStep2RepairmachinedefectsandleaksPurpose:TorepairitemsfoundinStep1Considerations:Champion/SponsorinsurestaggedproblemsarerepairedActualrepairsdonothavetobedonebyteammembersProductionSupervisorhastomakemachineavailable66TPMStep2Repairmachinedefec66TPM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(rùn)滑調(diào)試檢查/測(cè)試67TPM步驟2消除故障因素6767TPMStep2Eliminatefactorscontributingtofailure:Secureandtightenallfasteners,fittings,boltsandscrewsReplaceanymissingpartsReplaceanydamaged,wornorwrongsizepartsResolveallcausesofleaks,spillage,sprayandsplatterImproveaccessibilityinordertoaccomplish:Cleaning LubricatingAdjustingChecking/inspecting68TPMStep2Eliminatefactorsco68TPM步驟3建立操作員和維護(hù)人員合作的PM計(jì)劃確保發(fā)出完善的定期檢測(cè)的查檢表目的:注意事項(xiàng):由TPM項(xiàng)目小組建立PM計(jì)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)69TPM步驟3建立操作員和維護(hù)人員合作的PM計(jì)劃6969TPMStep3DevelopOperatorPM’sandMaintenancePM’sPurpose:ToinsureadequatepreventativemaintenancechecklistsarepostedConsiderations:TPMProjectTeamtodevelopPM’sWhoistoperformtasksFrequencyoftasks(i.e.,daily,weekly,etc.)70TPMStep3DevelopOperatorPM’70TPM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(xiàng):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(shí)施71TPM步驟4由操作員執(zhí)行的PM作業(yè)7171TPMStep4PMactivityperformedbytheOperatorPurpose:Todetectearlyproblems,providetheserviceinterval,andinsure5SprocedureisfollowedConsiderations:OperatorisresponsibletoperformPM’sasdocumentedProductionSupervisortoinsurePM’sareeffective72TPMStep4PMactivityperforme72TPMTPM使操作員更加獨(dú)立地自我管理和控制;操作員時(shí)時(shí)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73TPMTPM使操作員更加獨(dú)立地自我管理和控制;7373TPMTPMmakestheoperatormoreindependentTheoperatorseesthesmallproblemsnowwiththepossibilityof: QuicklynotingpotentialproblemsCorrectingthecurrentsituationRecognizingnormalconditionsMaintainingthemachineingoodoverallcondition74TPMTPMmakestheoperatormore74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(shí)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(cè)進(jìn)行基本的操作,維護(hù)及故障檢測(cè)的培訓(xùn)使日常作業(yè)直觀,一目了然明確識(shí)別須監(jiān)督管理的項(xiàng)目75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)7575AutonomousMaintenanceReferstoactivitiesinvolvingoperatorsinthemaintenanceoftheirownequipmentHowtomaketheoperatormoreindependent:MakedocumentationavailableDefinemaintenance/manufacturingactivitiesShowoperatorhowtoperformdailychecksTraininbasicoperation,maintenance,anddefectdetectionMakedailyactivitiesvisibleClearlyidentifyitemstosupervise76AutonomousMaintenanceReferst76落實(shí)自主維護(hù)管理確定過程實(shí)施中的關(guān)鍵機(jī)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(rùn)滑標(biāo)準(zhǔn)就設(shè)備的保養(yǎng)需求對(duì)操作員進(jìn)行培訓(xùn)貫徹實(shí)施一個(gè)綜合性的維護(hù)系統(tǒng)對(duì)保養(yǎng)效果進(jìn)行定期審查77落實(shí)自主維護(hù)管理確定過程實(shí)施中的關(guān)鍵機(jī)器及設(shè)備7777AutonomousMaintenanceImplementationIdentifyprocesscriticalmachineryandequipmentPerforminitialcleaningResolvesourcesofdirtandcontaminationCreatecleaningandlubricationstandardsTrainoperatorsonequipmentmaintenancerequirementsImplementacomprehensivemaintenancesystemEstablishperiodicauditsofmaintenanceeffectiveness78AutonomousMaintenanceImpleme78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(huì)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79為什么清潔?不恰當(dāng)?shù)那鍧嵥鶐淼呢?fù)面影響:7979WhyClean?AdverseeffectsofinadequatecleaningFailureProductdefectsAccelerateddeteriorationThroughputlossEquipmentdeteriorationNormaldeterioration:occursdespitecorrectuseAccelerateddeterioration:quickerdeteriorationoccurringduetomisuseinoperationandneglectofmaintenance80WhyClean?Adverseeffectsofi80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(zhǎng)使用壽命,避除故障81清潔可作為磨損檢查清潔可減緩磨損速度8181CleaningasDetectionofDeteriorationCleaningreducesaccelerateddeteriorationPhysicalcontactwithequipmentexposesabnormaloperationconditionsPreventiveactiontakenextendsusefullifeandavoidsbreakdowns82CleaningasDetectionofDeter82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83常見的設(shè)備缺陷斷線8383TypicalDefectsFoundBrokenflexWornhosesOilleaksAirLeaksCoolantleaksBrokenBracketsFrayedwiresUnnecessaryandobsoletetoolingDamagedormissingguards84TypicalDefectsFoundBrokenfl84設(shè)備故障專家估計(jì)與移動(dòng)裝置相關(guān)的機(jī)器故障有60%是由于缺乏或不適當(dāng)?shù)臐?rùn)滑導(dǎo)致的;建立設(shè)備故障資料庫(kù)收集并管理故障資料分析故障趨勢(shì)及形式定期展開和發(fā)布總結(jié)報(bào)告包括用于定期回顧之用的會(huì)議議程報(bào)告85設(shè)備故障專家估計(jì)與移動(dòng)裝置相關(guān)的機(jī)器故障有60%是由于缺乏或85EquipmentFailuresExpertsestimatethat60%ofmachinebreakdownsassociatedwithmovingpartsareduetolackoforimproperlubricationpractices.EstablishanequipmentfailuredatabaseGatherandmanagefailureinformationAnalyzefortrendsandpatternsDevelopandissueperiodicsummaryreportsIncludereportsasameetingagendaforregularreview86EquipmentFailuresExpertsesti86TPM步驟4(續(xù)）目視管理張貼設(shè)備潤(rùn)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87TPM步驟4(續(xù)）目視管理8787TPMStep4（Con.)VisualsControlsLubricationplacardsinplaceUpperandlowersightglassesinplaceAllair,water,gas,andcoolantlinesarelabeledOEEpostedYTDMaintenancecostsposted5SAuditScoresposted88TPMStep4（Con.)VisualsCont88TPM步驟5由維護(hù)人員執(zhí)行的PM作業(yè)目的:預(yù)防機(jī)器故障在發(fā)生故障之前解決注意事項(xiàng):PM作業(yè)內(nèi)容由維修及生產(chǎn)人員共同訂立保全主管須確保PM作業(yè)的有效性89TPM步驟5由維護(hù)人員執(zhí)行的PM作業(yè)8989TPMStep5PMactivityperformedbyMaintenancePersonnelPurpose:Topreventmachinefailure-fixbeforefailureConsiderations:PM’sarescheduledjointlybyMaintenanceandProductionMaintenanceSupervisortoinsurePM’sareeffective90TPMStep5PMactivityperform90TPM步驟6貫徹5S現(xiàn)場(chǎng)管理及組織體系確保維持清潔成果及團(tuán)隊(duì)執(zhí)行:整理 清理掉無用的及已經(jīng)損壞的東西整頓 要用的東西依規(guī)定定位,明確標(biāo)示清潔 清除臟污,防止污染,保持從上到下的清潔標(biāo)準(zhǔn)化 規(guī)范保養(yǎng)頻次素養(yǎng) 長(zhǎng)期改善,養(yǎng)成好習(xí)慣91TPM步驟6貫徹5S現(xiàn)場(chǎng)管理及組織體系9191TPMStep6Implement5SHousekeepingandOrganizationPurpose:ToensuredsustainedcleanlinessandorganizationExecution:Sort RemoveobsoleteandbrokenequipmentSetInOrder EverythinginadesignatedplaceShine ToptobottomcleaningStandardize AllowtimeandmaintainfrequencySustain Longtermimprovement92TPMStep6Implement5SHouseke92TPM步驟7監(jiān)控設(shè)備綜合利用率OEE,鼓勵(lì)合作目的:不斷總結(jié)并改善機(jī)器的性能并加強(qiáng)維修和生產(chǎn)部門的合作注意事項(xiàng):需要定期進(jìn)行TPM工作總結(jié)追蹤現(xiàn)行的活動(dòng)進(jìn)度狀況確定下一個(gè)需改善的區(qū)域需要時(shí)采取校正措施93TPM步驟7監(jiān)控設(shè)備綜合利用率OEE,鼓勵(lì)合作9393TPMStep7MonitorOEEandencouragecooperationPurpose:TocontinuouslyreviewandimprovemachineperformanceandcooperationbetweenMaintenanceandProductionConsiderations:HaveregularlyscheduledTPMreviewsTrackprogressofongoingactivitiesIdentifyareasforfutureimprovementsInitiatecorrectiveactionwhenneeded94TPMStep7MonitorOEEandenco94TPM步驟7

TPM衡量指標(biāo)對(duì)任一過程,衡量指標(biāo)都能既監(jiān)控過程性能又表現(xiàn)TPM效果設(shè)備的利用率(OEE)可用水平AL作業(yè)水平OL質(zhì)量水平QL設(shè)備綜合利用率OEE故障平均間隔時(shí)間(MTBF)維修平均間隔時(shí)間(MTTR)95TPM步驟7

TPM衡量指標(biāo)對(duì)任一過程,衡量指標(biāo)都能既監(jiān)95TPMStep7

TPMMetricsAswithanyprocess,MetricsareneededtobothmonitorprocessperformanceandunderstandgainsmadefromtheTPMeffortOperationEquipmentEffectiveness(OEE)AvailabilityLevelOperatingLevelQualityLevelOEEMeanTimeBetweenFailure(MTBF)MeanTimeToRepair(MTTR)96TPMStep7

TPMMetricsAswith96知識(shí)獲取重點(diǎn)一個(gè)完善的TPM程序可以:加快對(duì)客戶反應(yīng)速度減少機(jī)器停工時(shí)間改善品質(zhì)增強(qiáng)工作安全性降低成本,提高利潤(rùn)建造愉快的工作氛圍增進(jìn)合作降低工業(yè)污染降低庫(kù)存水平97知識(shí)獲取重點(diǎn)一個(gè)完善的TPM程序可以:9797TakeawaysAsolidTPMprogramresultsin:ImprovedresponsetimetocustomerReducedmachinedowntimeImprovedqualityIncreasedjobsafetyReducecostandincreasedprofitsProvidesapleasantworkingatmosphereImprovedlevelsofcooperationReducedindustrialpollutionReducedinventorylevels98TakeawaysAsolidTPMprogramr98InstructorNotes

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andRevision99ChapterRevisionHistoryHiddenSlide100ChapterRevisionHistoryHidden1002022/12/10TPM全面生產(chǎn)維護(hù)2022/12/10TPM全面生產(chǎn)維護(hù)101TotalProductiveMaintenance(TPM)TPMTPMTeamOrganizationOverallEquipmentEffectivenessTPMPhasesRD011202TotalProductiveMaintenance(102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(xiàng)目焦點(diǎn)和重要指標(biāo)完成PDF測(cè)量繪制業(yè)務(wù)流程圖繪制價(jià)值流程圖制定數(shù)據(jù)收集計(jì)劃測(cè)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(yàn)證關(guān)鍵因子評(píng)枯每個(gè)關(guān)鍵因子對(duì)結(jié)果的影響量化機(jī)會(huì)根本原因排序?qū)ふ腋驹蜥槍?duì)關(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(shí)行方案控制過程變革和控制制定控制計(jì)劃計(jì)算最終財(cái)務(wù)過程指標(biāo)項(xiàng)目過渡給未來項(xiàng)目管理者項(xiàng)目鑒別轉(zhuǎn)化機(jī)會(huì)測(cè)量定義項(xiàng)目編號(hào)工具項(xiàng)目定義表凈現(xiàn)值分析內(nèi)部回報(bào)率分析折算現(xiàn)金流分析PIP管理過程RACIQuad表過程圖價(jià)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(yùn)行圖控制圖量具R&RCp&Cpk供應(yīng)鏈加速器分析多變動(dòng)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(yàn)力場(chǎng)分析圖樹狀圖甘特圖查檢表運(yùn)行圖柱狀圖散布圖控制圖柏拉圖互動(dòng)回顧愚巧法Revised1-12-02103精益6

過程改善流程分析控制改進(jìn)定義測(cè)量分析改進(jìn)控制測(cè)103LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

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AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

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