設(shè)備自主維護(hù)

AutonomousMaintenance自主維修

Guidelines指導(dǎo)方針NHAGNHCETherearetwotypesofautonomousactivities:oneisfocusedontheareaswithintensivemachineryandtheotherontheareaswithahighleveloflaborcontent.有兩種自主維修活動(dòng)，一是重點(diǎn)放在加強(qiáng)機(jī)器區(qū)域，另一個(gè)是勞力較多的區(qū)域。TheactivityregardingthemachineryiscalledAutonomous

MaintenanceandtheactivityregardingtheorganizationoftheworkareaiscalledWorkplaceOrganization關(guān)于機(jī)器方面的活動(dòng)叫自主維修，關(guān)于工作區(qū)域組織的活動(dòng)叫工作場(chǎng)所組織。AutonomousMaintenance自主維修Theautonomousmaintenanceispartofthoseactivitiesthathasasthemainscopetopreventbreakdownsandmicrofailuresduetolackofbasicconditionsofthemachines.自主維修是那些活動(dòng)的一部分，這些活動(dòng)能夠預(yù)防由于機(jī)器基本條件缺乏造成的損壞和小故障。Theautonomousmaintenanceisnotatechnicalactivity,liketheprofessionalmaintenance,butitmustbelearnedandappliedbyallthepeoplethatinteracteverydaywiththemachines.It’sbasedonthecompetenciesoftheoperatorsandusingthefivesensesandverysimpletoolslikepaintbrushestoeliminatethedirt,plastictoprotectthemachineryetc.自主維修不是一種技術(shù)活動(dòng)，像專業(yè)維修，但是每天使用機(jī)器的人都要學(xué)會(huì)應(yīng)用此自主維修技術(shù)。它是在操作工能力基礎(chǔ)上的，用五官，使用很簡(jiǎn)單的工具，如用油漆刷來清除污漬，用塑料保護(hù)機(jī)器等。WhatisAM?(1/2)什么是自主維修？ThetypicaloperationsofAMarecleaning,lubrication,adjustmentoffasteners,parameterscontrol,temperaturecontrol,noiseandvibrationcontrol,minorrepairsandminorimprovements.自主維修典型的操作是清潔，上油，調(diào)節(jié)閥，參數(shù)控制，溫度控制，噪音和振動(dòng)控制，小修復(fù)和小改善。TheAMisasystematicapproachtowardsthemachineryimprovementwiththeobjectivetoautonomouslymanage,bytheproductionoperators,theinspections,thecontrolandrestorationofthebasicconditionsofthemachineryeliminatingthesourcesofdirt,throughastrictapplicationandacontinuousimprovementofthestandards.自主維修是進(jìn)行機(jī)器改善的系統(tǒng)方法，擁有自主管理的目標(biāo)，由生產(chǎn)操作工清除污漬來源，通過嚴(yán)格遵守運(yùn)用不斷改善的標(biāo)準(zhǔn)，進(jìn)行檢查，控制和恢復(fù)機(jī)器的基本條件。RegardingAMandPM,uptostep3,it’sveryimportanttoalwayskeepseparatedthepreventiveactivitiesamongstthetwopillars.關(guān)于自主維修和專業(yè)維修，一直到步驟3，要一直將兩支柱中的預(yù)防性維修分開很重要。WhatisAM?(2/2)什么是自主維修？Themachinescanbreakbecauseofdeterioration,increasingofthestressthattheyshouldsupport,causedbythelossofbasicconditions.Likewisetheycanbreakduetohumanerrorsortodesignerrors.

機(jī)器可能損壞，是因?yàn)槟p，所能承受的壓力增加，基本條件缺乏造成的。同樣，也可以是人為失誤或設(shè)計(jì)錯(cuò)誤造成的。Whydothemachinesbreak?(1/2)機(jī)器為什么會(huì)損壞呢？BREAKDOWN損壞DETERIORATION磨損EXCESSIVESOLICITATIONS額外的引發(fā)SCARCEROBUSTNESS不夠耐用1Lackofmaintainingthebasicconditions維修基本條件缺乏23465Lackofobservancyoftheoperatingconditions不遵守操作條件Norestorationoftheanomalies沒有對(duì)異物進(jìn)行恢復(fù)Designweakness設(shè)計(jì)不足Badcompetenciesofoperatorsandmaintenancepeople操作工和維修人員的能力差Externalinfluences:material,spareparts,environmentecc.外部影響：材料，備用零件，環(huán)境等。Whydothemachinesbreak?(2/2)機(jī)器為什么會(huì)損壞？Thedeterioration

happensastimegoesoncausedbyabadmaintenancenotableto“maintain”thebasicconditionsorbythebadcompetenciesoftheoperatorswhomdonotperformcorrectlytheinspections.由于維護(hù)不當(dāng)，不能維護(hù)基本條件或能力差的操作工不能正確的完成檢查，時(shí)間久了就會(huì)發(fā)生磨損。Theincreaseofstressandtheexcessivesolicitationsareduetooperatingerrors(badcompetenciesoftheoperators),badinterventionsorduetothefactthattheoperatingconditionsarenotstrictlyobservedbytheoperatorsandofthenonobservanceofthebasicconditions.由于操作失誤（操作工能力差），不良干涉或操作工不能嚴(yán)格遵守操作條件及不遵守基本條件，導(dǎo)致壓力增加，額外的引發(fā)出現(xiàn)。Thescarcerobustnessofthemachineryistheresultsoferrorsorweaknessofthedesignsofthemachinesorsinglecomponents,ofconstructionorinstallationerrors.Toavoidthedeteriorationofthemachinery,itisnecessarytoassurethemaintenanceofthebasicconditions.Thisispossiblethroughthepreventivemaintenance,activitiescarriedoutbytheAMandPMpillars.機(jī)器不耐用是因?yàn)闄C(jī)器零件的設(shè)計(jì)、構(gòu)造錯(cuò)誤或不足，或安裝錯(cuò)誤。為了避免機(jī)器磨損，保證機(jī)器的基本條件很重要?？梢蚤_展由AM和PM支柱執(zhí)行的維修活動(dòng)。Inordertoavoiderrorsdonebyoperatorsormaintenancepeople,whocangeneratetheincreasingofstress,trainingmustbedone.為了避免由能產(chǎn)生壓力增加的操作工或維修人員造成的失誤，必須要進(jìn)行培訓(xùn)。Toavoiderrorsduetodesignweaknesses,theEarlyEquipmentManagementpillartakesparttosolvetheissues.為了避免由于設(shè)計(jì)不足造成的錯(cuò)誤，設(shè)備初期管理支柱要加入解決此問題。AM:Objectives自主維護(hù)：目的Inthefirstphase,theobjectiveoftheAMisthemaintenanceofthe

basicconditionsofthemachinery.Thisisachievableassuringthecorrectoperatingstandardsofthemachinery,thecleanliness,thelubricationandsafety.第一階段中，AM的目的是維護(hù)機(jī)器的基本條件。保證正確的機(jī)器操作標(biāo)準(zhǔn)，確保清潔，潤(rùn)滑和安全，這是可以實(shí)現(xiàn)的。ThefinalscopeoftheAMistostabilizetheconditionsofthemachinery,improvetheirreliabilityandtoobtainasaresultthelengtheningoftheirlifetime.AM的最終目標(biāo)是穩(wěn)定機(jī)器的條件，改善其可靠性并實(shí)現(xiàn)機(jī)器使用壽命的延長(zhǎng)。Thispresupposesthedefinitionandthecontinuousimprovementofthemaintenancestandardsandtheincreaseofthecompetenciesoftheoperatorsintermsofknowledgeofthemachines.AveryimportanteffectoftheAMisthequalityimprovementofthemachineregardingtheproduct.這預(yù)示著維修標(biāo)準(zhǔn)的定義和不斷改善，及操作工就機(jī)器方面能力的增加。自主維修的一個(gè)非常重要的作用是涉及生產(chǎn)的機(jī)器質(zhì)量改善。Initialcleaning&inspection初步清潔和檢查Countermeasuresagainstsourcesofcontamination處理污染來源的對(duì)策Initialstandards初步標(biāo)準(zhǔn)Generalinspection全面檢查Autonomousinspection自主檢查Improvementofstandards(workplaceorganization&housekeeping)工作場(chǎng)所組織和設(shè)備管理、保養(yǎng)標(biāo)準(zhǔn)的改進(jìn)Full-scaleapplicationoftheautonomousmaintenancesystem全面貫徹自主維護(hù)系統(tǒng)TheSevenStepsofAutonomousMaintenance–AM自主維護(hù)的7個(gè)步驟Step1Step2Step3Step4Step5Step6Step7The7steps7個(gè)步驟Thescopeofthefirstthreestepsistogeneratechangesinthemachines,passingfromconditionsofdirtiness,ofdifficultyincleaningthemachines,hazardousness,slowness,unreliabilityandofbreakdownsandstoppagestoaconditionofcleanliness,safety,reliability,zerostoppagesandzerobreakdowns.前三步是為了改變機(jī)器，解決污穢情況及難以清洗的機(jī)器問題，將危險(xiǎn)，緩慢，不可靠和損壞，停頓情況轉(zhuǎn)變?yōu)榍鍧崳踩?，可靠，零停頓和零損壞狀態(tài)。

Thestep2isthemostcriticaloneforobtainingadvantagesthatderivefromAM.Theactivitiesofthefirsttwostepsaretypicallyofareactiveapproach.Theapplicationofsteps1-3istheKEYtodeterminethebasicconditionsofthemachine.第二步是AM取得優(yōu)勢(shì)的最關(guān)鍵步驟，前兩步是回應(yīng)方法的典型代表。步驟1到3的運(yùn)用是決定機(jī)器基本狀態(tài)的關(guān)鍵。The7stepsThefourthandfifthsteparefinalizedtogenerateachangeinthepeople,infacttheinspectionsdonedirectlybytheoperatorscreatescomprehensionandassumptionofresponsibilitytowardswhatandhowtocontrol,eventowardsquality,andmakesworkeasier.Theoperatorsgraduallyassumethecapabilitytoaccomplishautonomouslythemaintenanceactivitiesjustlikeaparentwoulddowiththehealthofhischildrencallingthedoctor,thatcanbecomparedtothemaintenancetechnicianincaseofnecessityforproblemsonthemachinery.It’simportanttoconsiderthefactthattheimplementationofstep4

isexpensiveintermsoftimeandmoney.It’simportanttopayattentiontothecostbenefitofthisstepinordertojustifytheimplementation.Theactivitiesofsteps3-4-5aretypicallyofapreventiveapproach.第4步和第5步是為了改變?nèi)?，?shí)際上由操作工直接執(zhí)行的檢查創(chuàng)造出對(duì)要控制什么，該如何控制及對(duì)質(zhì)量的理解和責(zé)任，并且是工作變得更加容易。漸漸地，操作工就有責(zé)任，有能力自主完成維修活動(dòng)，就像父母為了孩子的健康而找醫(yī)生一樣，這可以與萬一機(jī)器出現(xiàn)問題，必須要找維修技術(shù)員相比。就時(shí)間和金錢而言，考慮執(zhí)行步驟4的花費(fèi)很大很重要。為了證明此步的執(zhí)行是有效的，注意成本收益很重要。步驟3、4、5是預(yù)防性方法的典型代表。Thescopeofthesixthandseventhstepsistogeneratealong-lastingchangeinthemaintenancemanagementacrossanewmanagementsystemofautonomousactivitieswheretheworkerisresponsibleforhisareaintermsofqualityandreliabilityofthemachines.第6步和第7步是為了對(duì)維修管理進(jìn)行長(zhǎng)期的改變，形成新的自主活動(dòng)管理系統(tǒng)，該活動(dòng)中，工人們負(fù)責(zé)管理自己區(qū)域內(nèi)的機(jī)器的品質(zhì)和可靠性。Contentsofthe7steps–AM

自主維修的7個(gè)步驟的內(nèi)容StepContentsOfStep步驟的內(nèi)容0Educationofmachinefunction&condition對(duì)機(jī)器性能和狀態(tài)的學(xué)習(xí)1InitialCleaning&Inspection初步的清潔和檢查2Countermeasurestoeliminatesourcesofcontaminationand“hardtoaccess”areas清除污染來源和難以清洗區(qū)域的對(duì)策3Developprovisionalstandardsforcleaning,lubrication&tightening制定清洗，上油和上緊的臨時(shí)標(biāo)準(zhǔn)4GeneralInspection–Training&Instructionofthefinalizedstandards全面檢查-對(duì)最終標(biāo)準(zhǔn)的培訓(xùn)和指導(dǎo)5AutonomousInspection自主檢查6Reorganizingworkplace&Standardization重組工作場(chǎng)所并標(biāo)準(zhǔn)化7FullImplementationofAutonomousMaintenance全面貫徹自主維修Motivation動(dòng)機(jī)MachineChange機(jī)器改變PeopleChange人員改變WorkplaceChange工作場(chǎng)所改變RestorationofBasicConditions基本狀態(tài)的恢復(fù)PreventionofDeterioration預(yù)防磨損OptimizeStandardizeSelfManagement使自身管理最優(yōu)化，標(biāo)準(zhǔn)化2ELIMINATIONOFCAUSESOFLOSS清除損失原因3STANDARDCLEANINGLUBRICATION標(biāo)準(zhǔn)清洗潤(rùn)滑油4GENERALINSPECTION全面檢查5INDEPENDENTINSPECTION獨(dú)立檢查6AREACONTROLANDMANAGEMENT區(qū)域控制和管理7COMPLETEAPPLICATIONOFAUTONOMOUSMAINTENANCE自主維護(hù)的全面運(yùn)用INITIALCLEANING初步清潔1THOROUGHELIMINATIONOFDIRTFROMPLANTS對(duì)工廠污垢的徹底清除LEARNINGTHAT‘CLEANINGISINSPECTING’學(xué)習(xí)“清潔就檢查”REMOVALOFCAUSESOFDIRT/LOSSES除去污垢/損失原因REMOVALOFOBSTACLESTOACTIVITIES除去阻礙活動(dòng)的障礙物REDUCTIONOFCLEANING,LUBRICATIONTIMES減少清潔，上油時(shí)間DEFINECLEAR,SIMPLECLEANING,LUBRICATION,TIGHTENINGCONTROLSTANDARDS;SPECIFYTIMESANDFREQUENCY定義清潔，簡(jiǎn)單的清洗；固定控制標(biāo)準(zhǔn)；指定次數(shù)和頻率IMPROVETHEABILITYTOMAKEAGENERALINSPECTIONOFTHEPLANTACCORDINGTOSTANDARDSANDMANUALS根據(jù)標(biāo)準(zhǔn)和指南來提高全面檢查工廠的能力IMPROVETHEABILITYTOCARRYOUTINDEPENDENTINSPECTION,PREVENTIVEMAINTENANCECYCLESANDTOUSETHECHECK-LISTS提高執(zhí)行獨(dú)立檢查，預(yù)防性維修周期，使用核對(duì)表的能力STANDARDIZEMONITORINGOFTHEEFFICIENCY,OFSTOCKS,QUALITY,對(duì)效率，庫存和質(zhì)量的標(biāo)準(zhǔn)華監(jiān)控IMPROVEDATACOLLECTION;改進(jìn)數(shù)據(jù)收集MANAGETHEEQUIPMENTANDTYPECHANGES管理設(shè)備，類型改變INTEGRATEDMANAGEMENTOFAUTONOMOUSMAINTENANCEWITHREGARDTOOTHERASPECTSOFTPMANDPURSUITOFCONTINUOUSPERFORMANCEIMPROVEMENTGOALS涉及到TPM其它方面的自主維修的綜合管理，追求，完成不斷改善目標(biāo)The7stepsofautonomousmaintenance自主維修的7個(gè)步驟Timetable時(shí)間表Averagetimeofimplementationofthefirst4stepsofAM自主維護(hù)的前4步執(zhí)行的平均時(shí)間0-2nd.Step0-2步3rd.Step第3步ModelArea示范區(qū)100days100天1year1年3/6months3到6個(gè)月Extensionofthe3rd.Steptoalltheplant將第3步擴(kuò)展到整個(gè)工廠內(nèi)Implemetationof4th.Steponthemodelarea在示范區(qū)執(zhí)行第4步

PreliminaryactivitiesnecessaryforacorrectdefinitionandimplementationofAM:正確定義和執(zhí)行AM所必需的初步活動(dòng)：MatrixCofCostdeploymentanalysisandindividualizationoflossesduetobreakdowns.成本部署分析的C矩陣及由損壞造成的損失的特性Machineclassification機(jī)器分類.Targetdefinition:eg.Reductionof90%cleaningtimeonthemodelarea,max1breakdownpermonthonmodelarea,zerobreakdownsonthecriticalmachineduetolackofbasicconditions.目標(biāo)定義：如，示范區(qū)有90%的清潔時(shí)間減少，每月示范區(qū)最多損壞一次，由于基本條件缺乏的重要機(jī)器實(shí)現(xiàn)零故障。Individualizationofmodelarea.使示范區(qū)個(gè)性化Teamcomposition.團(tuán)隊(duì)合成PlanningofAMprojects.AM項(xiàng)目的計(jì)劃Step0–Preparation步驟0-準(zhǔn)備Paintshop噴漆車間CabAssemblyTractorAssemblyDrivelineAssemblyStep0–ModelArea步驟0-示范區(qū)Trainingoftheoperatorsofthemodelareadonebythemaintenanceguys“theteamleaderandtheoperatorsmustbecomeownersofthemachine”(explainhowthedeteriorationoccurs,diffusetheknowledgeregardingtheimportanceofsafetyduringAMactivities,developknowledgeonhowthemachineworks)andanalysis/executionoffunctionalschemesofthemachines.由維修人員執(zhí)行的示范區(qū)的操作工的培訓(xùn)，“小組領(lǐng)導(dǎo)和操作工一定要成為機(jī)器的擁有者”（解釋磨損是如何發(fā)生的，在自主活動(dòng)期間，傳播安全重要性方面的知識(shí)，開發(fā)機(jī)器是如何運(yùn)作方面的知識(shí)）并分析或?qū)嵤?duì)機(jī)器有作用的計(jì)劃。PredispositionofallnecessarymaterialsforAM(Rags,detergent,paintbrushes,Tags,formatsfordatacollectionetc.)AM中所有必需材料傾向的狀態(tài)（碎片，清潔劑，油漆刷，標(biāo)簽，數(shù)據(jù)收集的版式等）Step0–ModelArea步驟0-示范區(qū)Step0–Preparation步驟0-準(zhǔn)備Input輸入MatrixCofCostDeployment成本部署C矩陣Machinesclassification機(jī)器分類Output輸出Radarchartoftheteam小組雷達(dá)圖Masterplanincludingactivitiesforeachstep,auditsandcorrectiveactionsnecessaryforsolvingthecriticalitiesfoundduringtheaudits總體規(guī)劃，包括每一步的活動(dòng)，審核和處理危險(xiǎn)程度所必需的矯正行為，該危險(xiǎn)程度是審核過程中發(fā)現(xiàn)的。Team團(tuán)隊(duì)-Operators/Maintenancepeople.TheresponsibleoftheteamisthePillarleaderoftheplant操作工/維修人員，團(tuán)隊(duì)中的責(zé)任人是工廠內(nèi)的支柱領(lǐng)導(dǎo)。Tools工具OnePointlessonstodeveloptheskillsoftheoperators開發(fā)操作工技能的單點(diǎn)課程Radarchart雷達(dá)圖KPI’s關(guān)鍵業(yè)績(jī)指標(biāo)Know-howachievedbytheoperatorsandmeasuredwiththenumberofOPL’sandwithain-outtestofstep0;由操作工取得的技能并由單點(diǎn)課程數(shù)量和步驟零的內(nèi)外測(cè)試進(jìn)行衡量numberofoperatorsinvolvedinthemodelarea加入示范區(qū)的操作工人數(shù)Remarks備注OPLonsafetybeforestartingAMactivities開展AM活動(dòng)前的安全單點(diǎn)課程Fromstep1tostep2foreseeaninvolvementofthePMteaminordertoincreaseandconsolidatetheknowledgeoftheoperatorsregardingtheactivitiesofcleaning,inspection,lubricationandcontrol.為了增加，鞏固操作工在清潔，檢查，上油和控制方面的知識(shí)，步驟1到步驟2預(yù)知有PM團(tuán)隊(duì)加入。Step1–InitialCleaning步驟1-初步清潔Initialcleaningandinspectioninordertoremovedustanddirtthatarethesourcesofdeteriorationofthemachines.為了除去灰塵和污垢，要進(jìn)行初步的檢查，此灰塵和污垢是機(jī)器磨損的來源。Removedustanddirtofallthepartsofthemachine.除去機(jī)器上所有零件上的灰塵和污垢。Hangtagsonthemachineshowingalltheanomalies,sourcesofcontamination,hardaccesszoneswhichcancausequalitydefects.在機(jī)器上掛上標(biāo)簽，展示出可能造成質(zhì)量缺陷的所有的異物，污染來源，硬的接觸區(qū)。Removealluselessobjectsandcreatetidinessandcleanliness.移走所有無用的東西，創(chuàng)造整潔，清潔的環(huán)境。Writethelistofanomalies記下異物清單

...CLEANINGISINSPECTING清潔就是檢查MACHINECLEANED清潔的機(jī)器DIRTISREMOVED,CHIPS,SCRAPSAREREMOVED除去了污垢，碎片，廢料THEELEMENTSOFTHEMACHINERYARETOUCHEDWEARANDDOWNGRADINGISPREVENTED預(yù)防了磨損和降格THEPLANTISKNOWN工廠被大家所知IRREGULARFUNCTIONINGISIDENTIFIED不規(guī)則的機(jī)能已被鑒定WEARISCHECKED磨損已被檢查PREVENTION預(yù)防useman’s5sensesAppropriately適當(dāng)?shù)厥褂萌说?種感覺Step1–InitialCleaning步驟1-初步清潔Operatorslearnthatcleaningisinspection…操作工學(xué)習(xí)清潔就是檢查…improvingtheirabilitytotraceminorproblemsandtodiscoverirregularitiesduringcleaning在清潔期間，提高追蹤小問題，發(fā)現(xiàn)不整齊東西的能力。AimsofInitialcleaning初步清潔的目標(biāo)Step1:InitialCleaning步驟1：初步清潔I'llstarttocleanwitharagIhavealsogottoinspecttheinsidetheofmachine

Toomuchgrease!

Thecover’smissing!

Theoillevelisn’tvisible!

Too

muchdirt

andnotenoughgrease

Excessleakageofoil

Thisway,

I’lltraceallthefaults!

ThepressureisOK

Continuoustagging不停的加標(biāo)簽Indicationofissueoftag指出標(biāo)簽上的問題Shortcircuitduetosimpleproblems小問題造成的短路Repetitive(chronic)Causesunknown反復(fù)出現(xiàn)的（長(zhǎng)期的）未知原因Listoftags標(biāo)簽清單Tagsattached附上的標(biāo)簽Tagsremoved去掉的標(biāo)簽Action行動(dòng)SolvingoftheProblem問題的解決TeamLeader+BTULeader+GroupTeamLeader+BTULeader+Maintenance+Aut.Maint.Resp.Step1:initialcleaning步驟1：初步清潔

Step1–InitialCleaning步驟1-初步清潔Inthisphasetheoperators,afterreceivingthetrainingonsafety,howtoclean,whichtoolstousefortheactivitiesandhowtopayattentioninordernottocreatedamagestothemachine,theycanstarttheinitialcleaning.It’simportanttoremoveallthedirt,findalldefects,anomaliesandhiddenbrokenthingsplacingAMtagswheretheproblemsare.為了不給機(jī)器帶來損壞，此階段中的操作工在受到安全，怎樣清洗，活動(dòng)中使用哪種工具，如何注意培訓(xùn)后，他們可以開始進(jìn)行清洗了。除去貼上AM標(biāo)簽地方的所有污垢，找出所有缺陷，異物和隱藏的損壞東西很重要。BeforeAfterBefore之前After之后

Step1–InitialCleaning步驟1-初步清潔

Step1–InitialCleaning步驟1-初步清潔Output輸出

Listofalltheanomaliesassigningresponsibilitiesanddeadlines.列出所有的異物，指明歸屬責(zé)任和截止時(shí)間Quantificationofcostbenefitsofthestep量化此步中的成本收益Suggestions建議Hoursoftrainingand/orOPL’s培訓(xùn)和/或單點(diǎn)課程的時(shí)間PlanofAMactivitiesforcleaningAM清潔活動(dòng)的計(jì)劃Team團(tuán)隊(duì)TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.AtthelaunchofthefirstAMactivity,it’srecommendablethattheplantmanagerispresentandactivelyparticipates,tocreateinvolvementandtogivetherightcommitment.此活動(dòng)中包括了示范區(qū)內(nèi)的所有操作工，由支柱領(lǐng)導(dǎo)指導(dǎo)。第一個(gè)AM活動(dòng)開展時(shí)，可以推薦廠長(zhǎng)出席并積極參加，呼吁人們參加并給出適當(dāng)?shù)脑u(píng)論。Tools工具AMtagsmustbeusedplacingthemneartheindividualizedanomaliesorcanbeusedtosuggestanimprovement.AM標(biāo)簽可被放在個(gè)別異物旁或被用于提出改善建議。TheAMtags,usually,areblueifsolvedbyoperatorsandredifsolvedbymaintenancepeople.該AM標(biāo)簽若是由操作工解決的就是藍(lán)色，若是維修人員解決的就是紅色。KPI’s

關(guān)鍵業(yè)績(jī)指標(biāo)

NumberofAMtagsperweek(considerthatforanaveragecomplexmachine,thenumberoftagsaftertwo/threeweeksofactivitiesofcleaningandinspectioninordertobeconsideredasuccess,itshouldbearound300/400tags.)每周的AM標(biāo)簽數(shù)（對(duì)于復(fù)雜程度一般的機(jī)器，考慮其2到3周的清潔檢查活動(dòng)后的標(biāo)簽數(shù)量，為了成功，標(biāo)簽數(shù)應(yīng)為300到400左右。）Implementationrate(Tags)執(zhí)行比率（標(biāo)簽）Numberofquickkaizens快速改善數(shù)量Savingsontechnicalcleanings技術(shù)清潔方面的節(jié)省Regardingthecalendar:hrs/week,hrs/weekofovertimeforAMactivities關(guān)于記錄表：AM活動(dòng)超時(shí)的時(shí)間（小時(shí)/周）Remarks備注Organizetheactivitieswithoutinterferencewithproductionorganizingthestoppagesororganizingwhenthemachinesarestopped(nightshift,Saturdays,Sundays)組織停產(chǎn)活動(dòng)，組織停頓或在機(jī)器停止時(shí)組織（夜班，周六，周日）Assuremaximuminvolvementofthepeopleontheshopfloor:e.g.Paintingthefloorofthemodelareawhitesothateveryonecan“see”thesourcesofdirtandsothateveryoneunderstandstheresponsibilityofkeepingtheworkplaceclean.確保車間人數(shù)最大量的參加：如，將示范區(qū)噴為白色，以便大家都能看到污垢來源，并讓大家明白保持工作場(chǎng)所清潔的義務(wù)。Godeepintheanalysisofeachcomponenttounderstandthenecessitytolubricateeveninvolvingthevendor.Weareusuallyconvincedthatwhatwelubricateisenoughbutifwegoindetailwefindoutthatthere

ismanyotherthingstolubricate.深入分析每個(gè)零件，明白上油的必要性，即便是聯(lián)系賣方。通常我們都相信我們所上的油足夠了，但是再仔細(xì)看來，還有許多其它東西要上油Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對(duì)策Individualizethesourcesofcontaminationandthehardaccesszones.個(gè)別加以考慮污染來源和硬的接觸區(qū)Findcountermeasuresforthesourcesofcontaminationandthehardaccesszones.找出污染來源和硬接觸區(qū)對(duì)策。Reducetimeforcleaning,inspectionandlubrication.清潔，檢查和上油的時(shí)間減少。Step2–countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對(duì)策‘Platecover’Lowcost,easytoapply成本低，易于應(yīng)用‘Boxtype’Lowcost,veryEffective成本低，很有效Changethematerialtoplastic,rubberorsheetsteel將材料變成塑料制品，橡膠或鋼板Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對(duì)策Before之前After之后Installationoftraytocollectchipsandoilfrommachining安裝托盤來收集加工時(shí)漏出的碎片和油Contaminationwithchipsandoilfrommachinedparts機(jī)械零件上的碎片和油漬污染CleaningTimeReduction清潔時(shí)間的減少M(fèi)achine:COMAUTransferLine Area:GearBox機(jī)器：COMAU傳遞線區(qū)域：傳動(dòng)箱Before之前After之后Otherresults:其它結(jié)果：CleaningTime(Minutes/day)Problem:difficultaccessduetotheshapeofthecovers問題：由于蓋子的形狀而難以接近Countermeasure:installationofmeshcoverswithsafetydevices對(duì)策：安裝安全裝置-網(wǎng)狀蓋子-53%EXAMPLEStep2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對(duì)策Extensionto6similartransfermachines延伸至6種類似的轉(zhuǎn)移機(jī)器-Eliminationoffloorslickness消除地板的光滑Step2–Countermeasuresagainstsourcesofcontamination–ActionPlan步驟2-清除污染來源的對(duì)策-行動(dòng)計(jì)劃Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對(duì)策Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對(duì)策Output輸出Listofallthesourcesofcontaminationandcountermeasuresfortheirtheelimination.列出所有的污染來源并找出相應(yīng)的清除對(duì)策Team團(tuán)隊(duì)-TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.該活動(dòng)包括示范區(qū)的所有操作工，且由支柱領(lǐng)導(dǎo)指導(dǎo)。Tools工具-Quickkaizens:PDCAactivitiesofproblemsolving快速改善：解決問題的PDCA活動(dòng)KPI’s關(guān)鍵業(yè)績(jī)指標(biāo)Numberofimplementedcountermeasuresindividualized.個(gè)別加以考慮的對(duì)策的實(shí)施數(shù)量Cleaningtimereduction清潔時(shí)間的減少Lubricationtimereduction.上油時(shí)間的減少Inspectiontimereduction.檢查時(shí)間的減少Costbenefitanalysisofthestep.此步的成本收益分析Breakdowntrendonthecriticalmachines重要機(jī)器的損壞趨勢(shì)Remarks備注Inthecostbenefitanalysis,takeinconsiderationalsothereductionofthecleaningtimeofthetechnicalcleaningsexecutedbyexternalcontractors.在成本收益分析中，也考慮由外商執(zhí)行的技術(shù)清潔時(shí)間的減少。Calculatealsothesavingscomingfromthereductionofmaterialsandenergydirectlylinkedwiththesourcesofcontamination(eg.Oilecc.)也計(jì)算直接聯(lián)系到污染來源的材料和能源的減少。（如：油等）Step3–Initialstandards步驟3-初步標(biāo)準(zhǔn)Createinitialstandardsforcleaning,inspection,lubrication,tightenings,visualcontrols,thatallowtheoperationswithlesstimeandefforts(specificatingwhichpartofthemachine,time,frequency,gaugesettingmanagement,assignementoftasksandresponsibilities.為清潔，檢查，上油，固定，可視化控制創(chuàng)建初步標(biāo)準(zhǔn)，用較少的時(shí)間和努力進(jìn)行操作，指明機(jī)器的某個(gè)部分，時(shí)間，頻率，設(shè)置管理的標(biāo)準(zhǔn)尺，任務(wù)和責(zé)任的分配。Improvetheeffectivenessofthestandardsintroducingvisualmanagement.

提高介紹可視化管理標(biāo)準(zhǔn)的有效性。Reducetozeroallbreakdownsduetolackofbasicconditions(lackofAM)ofthecriticalmachines.將由于關(guān)鍵機(jī)器缺乏基本條件（缺乏自主維修）造成的故障減為零。Problem問題

ONEPOINTLESSON(OPL)單點(diǎn)課程Comp.by:…..Dateoftraining培訓(xùn)日期Trainer培訓(xùn)者Pupil學(xué)生Improvement改善

Date:15/07/03Basicknowledge基本知識(shí)Topic:FLOWMETERS–visualcontrolofoperatingrange話題：流動(dòng)表-操作范圍的可視化的控制Plant:M.F.O.U.:ENGINESBTU:105OP.110SAIMPGRINDINGaOperatingrangehighlightedwithindicationinred(incorrectoperatingrange)andgreen(correctoperatingrange)用紅色突出不正確的操作范圍，綠色突出正確的操作范圍Signature簽名:INCORRECTOPERATINGRANGE不適當(dāng)?shù)牟僮鞣秶鶦ORRECTOPERATINGRANGE正確的操作范圍No.17exampleStep3–Initialstandards步驟3-初步標(biāo)準(zhǔn)Markmostimportantboltssoastoimmediatelydetect,withaninspection,anyloosening(whentheboltisloosethepaintlineissectioned)標(biāo)記最重要的螺栓以便立即進(jìn)行檢查出一切松動(dòng)（當(dāng)螺栓松動(dòng)時(shí)，油漆線就會(huì)被截成段）Makethemachineseasytoinspect使機(jī)器易于檢查Step3:defineinspection,cleaningandlubricationstandards

步驟3：定義檢查，清潔和上油標(biāo)準(zhǔn)Vibration振動(dòng)Temperature溫度Visualcontrolreducesthetimenecessaryforinspectingerrors可視化控制減少檢查錯(cuò)誤的必要時(shí)間Numberofbelts帶子的數(shù)量Wear,dirt,dust磨損，污垢，灰塵Tension張力1.MAKEHIDDENINSPECTIONPOINTSVISIBLE使隱藏的檢查點(diǎn)可視化2. LOCATEINSPECTIONPOINTS ATEYEHEIGHT以視覺高度定位查找檢查點(diǎn)MAKEHIDDENPARTS VISIBLE使隱藏零件可視化Step3:defineinspection,cleaningandlubricationstandards步驟3：定義檢查，清潔和上油標(biāo)準(zhǔn)Improvementofvisualcontrol可視化控制的改善Improveplantvisibilityinordertofacilitatemaintenance:為了便于維修，提高工廠的可視性：Usecolorsandlabels用顏色和標(biāo)簽Displayfluidlevels顯示液面高度Makebeltandgearmovementsvisible使運(yùn)輸帶和齒輪運(yùn)轉(zhuǎn)可視化Displaytemperatures,operatingranges,flowsofcoolants,etc.顯示出溫度，操作范圍，冷卻液的流動(dòng)等。BEFORE之前AFTER之后GEARMOTORSARMASBTU6DIFFICULTTOCHECKCORRECTOILLEVELINGEAREDMOTOR很難檢查減速電機(jī)中正確的油位FAST,SAFECHECKINGOFCORRECTOILLEVEL對(duì)油位的準(zhǔn)快速，安全檢查Step3:defineinspection,cleaningandlubricationstandards

步驟3：定義檢查，清潔和上油標(biāo)準(zhǔn)D=DailyW=Weekly(Saturday)M=MonthlyBM=every2monthsSM=every6monthsA=AnnualDEPT.09PAGE1OF2INSTRUC.:MBU1030REV.:00of09.02.96ISSUEDBY:APPR.:AUTONOMOUSMAINTENANCEPLANMACHINE:CL.L.SAIMP-FORRESTTG.3830PROCESS:REDUCT.BOX/SEMISC.RINVIICleaningoftooltrolley清洗工具車Cleaningofareainsidemachine清洗機(jī)內(nèi)地方Cleaningofwatertank清洗水箱Cleaningofpallet清洗托盤Cleaninginsidetoolcribandoutside清洗工具箱內(nèi)外ReadingscaleaxisX-Y–Z閱讀比例軸XYZReplaceoilfilter+centraloilcartr.ReplaceoilcoolingairfilterFilter,electricalcabinetCheckonreadingscaleChecktach.dyn.brushes,motorsCheckefficientgroundconnectionCheckmotortake-offYaxisCleaninsideelectricalpanelCheckelec.andoverrunlimitswitchesReplacementspindlemotorfiltersINSPECTIONCLEANINGElim.dirtandchipsElim.dirtandchips-EliminatechipsPreventleaks–gen.cleaningAvoidcorrosionPreventmachinestoppagePreventmachinestoppageImprovesuctionAvoidreadingerrorsPreventmachinestoppageSafetySafetyPreventmachinestoppageSafetyMachinesafetyAircompr.suct./pist.Brush-shove.BrushAspireliquidsBrushorsuctiondeviceRagsandliquidDegr.scalew.alcoholReplaceReplaceReplaceVisualEmerypaper.+sprayTesterAmmeterRagsandsolventBlowingandsprayWrench,etc.WWSMWSMSMATMMSMSMSMSMSMSMSMOperat.Operat.CompanyOperat.2oper.Maint.Maint.Maint.Operat.Maint.Maint.Maint.Maint.Maint.Maint.Maint.YESYESYESYESYESYESYESYESYESYESYESYESYESYESYESYES2525-17400(200)(60)(30)(15)(60)(180)(15)(60)(30)(60)(45)WHATWHYHOWWHENWHOM.st.mM.washTimeExampleStep3:defineinspection,cleaningandlubricationstandards步驟3：定義檢查，清潔和上油標(biāo)準(zhǔn)Step3–Initialstandards步驟3-初步標(biāo)準(zhǔn)Output輸出

Autonomousmaintenancestandard/plan.Contains:thenameofthemachine,thecomponentsubdivision,thecleaningstandard,inspectionandlubricationforeachcomponent,themethodsandthetoolstoutilize,thefrequency,theresponsibility,thedailyplan(it’simportantthatthedetailsoftheplanaredailyandnotweeklyandthatontheplanarewrittenonlythebreakdownsthatareduetolackofbasicconditions(lackofAM).自主維修標(biāo)準(zhǔn)/計(jì)劃，包含：機(jī)器名稱，零件細(xì)分，清潔標(biāo)準(zhǔn)，每個(gè)零件的檢查和上油，使用方法和工具，頻率，責(zé)任，日常計(jì)劃（重要的是計(jì)劃的細(xì)節(jié)是日常的不每周的，計(jì)劃中僅記下由于基本條件缺乏（自主維修缺乏）造成的故障）Team團(tuán)隊(duì)-TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.這項(xiàng)活動(dòng)涉及到示范區(qū)所有的操作者并由支柱領(lǐng)導(dǎo)指導(dǎo)。Tools工具-OPL,SOP,AMplan單點(diǎn)課程，標(biāo)準(zhǔn)操作程序，自主維修KPI’s關(guān)鍵業(yè)績(jī)指標(biāo)

Costbenefitsofthestandards/plan標(biāo)準(zhǔn)/計(jì)劃的成本收益Costbenefitsoftheactivitiesdonefromstep0tostep3步驟0到步驟3內(nèi)執(zhí)行活動(dòng)的成本收益Breakdowntrendonthecriticalmachines.關(guān)鍵設(shè)備上的損壞趨勢(shì)Remarks備注Inordertoevaluatethecost/benefitsoftheactivitiesdonefromstep0tostep3it’snecessaryto:為了評(píng)估步驟0到3的活動(dòng)的成本/收益，必須要：Verify,foreachmachineunderAM,theeconomicallossreductionimprovementsignalizedbyCostDeployment;核實(shí)每個(gè)自主維修下的機(jī)器的由成本部署指出的經(jīng)濟(jì)損失減少改善Consolidatethesavingsofthetechnicalcleaningsexecutedbyexternalcontractors;鞏固由外商執(zhí)行的技術(shù)清潔節(jié)省Defineandcalculatethehoursofmaintenancemanpowersavedbytransferringthecleaning,inspectionandlubricationstandardstotheoperators;定義并計(jì)算人力維修時(shí)間，這些時(shí)間是將清潔，檢查和上油標(biāo)準(zhǔn)轉(zhuǎn)移給操作工節(jié)省的CalculatethecostsofAMintermsofmanpower,machinestoppages,tools,materialsandtraining;就人力，機(jī)器故障，工具，材料和培訓(xùn)計(jì)算自主維修成本SpecificAMmachineclassificationofthemachinesandcomponents(AA,A,B,C),includeintheclassificationthedataregardingbreakdownsduetolackofbasicconditionsthataresignalizedontheAMplan.機(jī)器和零件的具體自主維修機(jī)器分類(AA,A,B,C)，包括關(guān)于由于基本條件缺乏造成的故障的分類數(shù)據(jù)，這些基本條件是AM指出的。Step4–GeneralInspection步驟4-全面檢查Theobjectiveofthefirstthreestepsistoavoidthedeteriorationofthemachineryandthemaintenanceofthebasicconditions(cleaning,inspectionandlubrication).前三步的目標(biāo)是為了避免機(jī)器磨損和維修基本條件（清潔，檢查和上油）Step4isfundamentalforthetrainingoftheoperatorsonthetechnicalcharacteristicsofthemachines,inordertoincreasetheirabilityofdiscoveringthemalfunctioningsand,withthehelpofthespecialists,elaborateageneral

inspectionplan.Inthisstepthetrainingregardingqualityaspectsofthemachineandoftheproduct,intermsofparametersofthemachinethatcaninfluencethequality,isalsoimportant

.第四步是操作者對(duì)機(jī)器的技術(shù)特性的培訓(xùn)基礎(chǔ)，為了增加他們發(fā)現(xiàn)故障的能力，在專家的幫助下，闡述了一種全面檢查計(jì)劃。此步中的關(guān)于機(jī)器和產(chǎn)品質(zhì)量方面的培訓(xùn)也是很重要的，機(jī)器參數(shù)同樣也影響質(zhì)量。Step4–Activities(1/2)步驟4-活動(dòng)(1/2)

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