精益生產(chǎn)-全面生產(chǎn)維護(hù)tpm培訓(xùn)課件(ppt 100頁)

Measure Analyze Control Improve Lean Six Sigma 全面生產(chǎn)維護(hù) (TPM) uTPM uTPM 團隊組織 u設(shè)備綜合利用率OEE uTPM 活動步驟 RD011202 Measure Analyze Control Improve Lean Six Sigma Total Productive Maintenance (TPM) uTPM uTPM Team Organization uOverall Equipment Effectiveness uTPM Phases RD011202 Control Total Productive Maintenance (TPM)3 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 尋找根本原因針對關(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 RACI Quad 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 n消除導(dǎo)致設(shè)備故障的因素; n使設(shè)備的養(yǎng)護(hù)清潔更易達(dá)成; n用預(yù)測性保養(yǎng)作為一種檢測工具; n實施維護(hù)審查 Control Total Productive Maintenance (TPM)6 Learning Objectives uLearn a method to: nIntegrate operational productivity factors applicable in process industries in a single comprehensive measurement nEliminate factors contributing to equipment failure nImprove accessibility for cleaning and maintaining equipment nUse predictive maintenance as a diagnostic tool nImplement maintenance audits Control Total Productive Maintenance (TPM)7 個人學(xué)習(xí)意義 u流程作業(yè)和保養(yǎng)最優(yōu)化 u一種替代傳統(tǒng)的在故障發(fā)生時檢測并修復(fù)的方法; u一種源頭監(jiān)控和校正的先發(fā)系統(tǒng); u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; Control Total Productive Maintenance (TPM)8 Whats in It for Me? uOptimized process operations and maintenance uA method to replace the traditional approach of detecting and correcting faulty conditions as they occur uA proactive system which monitors and corrects causes uAn operations strategy based on understanding the cause and effect system affecting the major contributors to process performance Control Total Productive Maintenance (TPM)9 全面生產(chǎn)維護(hù) (TPM) 定義: u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。 Control Total Productive Maintenance (TPM)10 Total Productive Maintenance (TPM) TPM Definition uA common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance. Control Total Productive Maintenance (TPM)11 TPM u通過實施預(yù)防實現(xiàn)設(shè)備零故障和零缺陷; u預(yù)防工作將立足于以下方面: n維持正常的生產(chǎn)條件 n及早發(fā)現(xiàn)異常 n快速反應(yīng) Control Total Productive Maintenance (TPM)12 TPM uAchieve zero equipment breakdowns and zero defects through prevention uEstablish prevention by nMaintaining normal conditions nEarly detection of abnormalities nQuick response Control Total Productive Maintenance (TPM)13 傳統(tǒng)的反應(yīng)式維護(hù) 維修部門 “我們只管修理” n執(zhí)行所有的維修作業(yè) n往往是一旦設(shè)備發(fā)生故障充 當(dāng)救火員的角色; n負(fù)責(zé)定購和保管所有的工具, 備件等物資; n實施定期檢修 生產(chǎn)部門 ”我們只管使用“ n通常不作任何維護(hù)活動 n一旦設(shè)備出現(xiàn)故障就與維修 部門聯(lián)系 n維修作業(yè)中只能停工; n一直用到壞了為止 Control Total Productive Maintenance (TPM)14 Traditional Approach “Re-Active Maintenance” Maintenance “WE FIX” nPerform all maintenance activities nPerform “Fire Fighting” maintenance when a machine breakdown occurs nOrder and administer all tooling, supplies, etc. nPerform Preventive Maintenance Manufacturing “WE OPERATE” nGenerally does not perform any maintenance activities nContacts maintenance when a machine breakdown occurs nInactive during maintenance activities n“Run it till it breaks” Control Total Productive Maintenance (TPM)15 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. n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. n振動分析 n激光探測 n超聲波檢測 n發(fā)電機測試 n熱感應(yīng) n油況分析 預(yù)測性保養(yǎng)預(yù)測性保養(yǎng)定期保養(yǎng)定期保養(yǎng) Control Total Productive Maintenance (TPM)16 Key Definitions Preventive Maintenance is a time or usage based method of maintaining equipment. Maintenance activities are performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occurring. nPM Schedules Predictive Maintenance is a situation based method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring. nVibration Analysis nLaser Measuring nUltrasound nGenerator Testing nThermography nOil Analysis Predictive MaintenancePredictive MaintenancePreventive MaintenancePreventive Maintenance Control Total Productive Maintenance (TPM)17 現(xiàn)狀分析和團隊組織 u評估當(dāng)前的操作條件: n機器利用率,生產(chǎn)率等; n維修費用 (配件和人工) n對實現(xiàn)TPM的各項工作進(jìn)行優(yōu)先次序 u評估潛在TPM倡導(dǎo)者及團隊成員的實力 u挑選TPM倡導(dǎo)者及團隊成員 n建立初始的實施專門小組 n確定團隊目標(biāo) Control Total Productive Maintenance (TPM)18 Present State Analysis and Team Organization uAssess Current Operating Conditions nMachine utilization, productivity, etc. nMaintenance repair costs (parts and labor) nPrioritize order of TPM efforts uAssess capabilities of potential TPM Champions and Team Members uSelect TPM Champion and Team Members nEstablish initial kick-off workshop nEstablish team goal Control Total Productive Maintenance (TPM)19 典型的設(shè)備評價指標(biāo) u利用率: 設(shè)備實際運轉(zhuǎn)時間與總的可利用時間的比率; n= 實際運行時間/可運行時間 u效率: 實際產(chǎn)量與標(biāo)準(zhǔn)產(chǎn)量的比率 n= (實際產(chǎn)量/小時)/(標(biāo)準(zhǔn)產(chǎn)量/小時) u產(chǎn)出: 用一特定時間段的產(chǎn)量來衡量 n= 磅/小時, 件數(shù)/小時 Control Total Productive Maintenance (TPM)20 Typical Operational Process Measurements uUtilization: The ratio of equipment actual operating time to the total available operating time n= Actual Operating Time/Available Time uEfficiency: The ratio of actual product produced to a standard n= (Actual Parts/Hour)/(Standard Part/Hour) uOutput: Measure of output over a specified time period n= lbs/hr, pieces/hr Control Total Productive Maintenance (TPM)21 設(shè)備綜合利用率OEE u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. Control Total Productive Maintenance (TPM)22 Overall Equipment Effectiveness uOverall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality product at the designed rate. Control Total Productive Maintenance (TPM)23 OEE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. 可用水平可用水平 ( (AL)AL)運行水平運行水平 ( (OL)OL)質(zhì)量水平質(zhì)量水平 ( (QL)QL) Control Total Productive Maintenance (TPM)24 OEE Breakdown: The Six Big Losses Breakdowns and Minor Stoppages Malfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages) Setup Any activity related to equipment changeover, setup, or cleaning. Idling Time equipment is running but not producing product. Speed Losses Equipment operating at less than standard or design speed due to equipment/product abnormality Quality Factors Activities related to ensuring the quality of the product produced on the equipment (in -process checks). Rework Losses The time taken to re-process product or time take to produce un-usable product. Availability Level (AL)Availability Level (AL)Operating Level (OL)Operating Level (OL)Quality Level (QL)Quality Level (QL) Control Total Productive Maintenance (TPM)25 六大浪費的識別練習(xí) Control Total Productive Maintenance (TPM)26 Six Big Losses Identification Exercise Control Total Productive Maintenance (TPM)27 OEE的計算原理 承載時間 (LT) 設(shè)備運轉(zhuǎn)總的可利用時間 = 40 hrs 可用水平 (AL) 運行水平 (OL) 質(zhì)量水平 (QL) OEE73% x 91% x 80% 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% 40 OEE = 53% AL HRS = 40 - 3.1 - 3.8 - 4.2 = 28.9 hrs OL HRS = 28.9 - 3.1 - 1.1 = 26.3 hrs QL HRS = 26.3 - 3.1 - 2.1 = 21.1 hrs Control Total Productive Maintenance (TPM)28 Calculating OEE Elements Loading Time (LT) Total Hours Available for Equipment Operation = 40 hrs Availability Level (AL) Operating Level (OL) Quality Level (QL) OEE73% x 91% x 80% 26.3 - 3.1 - 2.1 = 80% 26.3 28.9 - 1.5 - 1.1 = 91% 28.9 Quality Factors Breakdowns Minor Stops, and Admin. Setup Speed Losses Idling Rework and Scrap 40 - 3.1 - 3.8 - 4.2 = 73% 40 OEE = 53% AL HRS = 40 - 3.1 - 3.8 - 4.2 = 28.9 hrs OL HRS = 28.9 - 3.1 - 1.1 = 26.3 hrs QL HRS = 26.3 - 3.1 - 2.1 = 21.1 hrs Control Total Productive Maintenance (TPM)29 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% x 95% x 99% 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% Control Total Productive Maintenance (TPM)30 World Class OEE Performance Loading Time (LT) Operation Time and PM Time is scheduled synchronizing the two Availability Level (AL) Operating Level (OL) Quality Level (QL) OEE90% x 95% x 99% Quality Factors Breakdowns Minor Stops, and Admin. Setup Speed Losses Idling Rework and Scrap OEE = 85% is World Class Performance The AL is consistently kept at or above 90% The OL is maintained at or above 95% The QL is at or above 99% Control Total Productive Maintenance (TPM)31 使設(shè)備恢復(fù)到可靠狀態(tài)使設(shè)備恢復(fù)到可靠狀態(tài) 消除故障消除故障 開發(fā)開發(fā)PMPM維護(hù)保養(yǎng)資料庫維護(hù)保養(yǎng)資料庫 消除缺陷消除缺陷 階段 I 階段 II 階段 III 階段 IV TPM 階段 Control Total Productive Maintenance (TPM)32 Return EquipmentReturn Equipment to Reliable Conditionto Reliable Condition EliminateEliminate BreakdownsBreakdowns Develop PMDevelop PM Information DatabaseInformation Database EliminateEliminate DefectsDefects PHASE I PHASE II PHASE III PHASE IV TPM Phases Control Total Productive Maintenance (TPM)33 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: n機器的啟動損失 n機器的故障損失 n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). Control Total Productive Maintenance (TPM)34 Six Team Activities 1. Use small group activities to improve machine uptime by eliminating the major sources of downtime. nStartup Losses nBreakdown Losses nMaterial and Scheduling Losses 2. Involve the machine operators as well as skilled trades in basic preventative maintenance such as lubrication, cleaning, and inspection for defects. Control Total Productive Maintenance (TPM)35 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 Control Total Productive Maintenance (TPM)36 Six Team Activities (Cont.) 3. Utilize predictive tools such as vibration analysis to move past reactive type maintenance 4. Increase awareness and knowledge of equipment to improve productivity and reduce downtime 5. Work with Supply Management and Production Control to insure a constant flow of raw material is available to preclude idling. 6. Develop manning schedules that insure that bottleneck machines are fully staffed Control Total Productive Maintenance (TPM)37 TPM的益處 u提升操作員的參與感 u使設(shè)備恢復(fù)至更高的性能水平 u發(fā)現(xiàn)并消除早期的設(shè)備隱患 u減少總的制造成本 u減少浪費 u在保養(yǎng)設(shè)備方面樹立榮譽感 u促進(jìn)維護(hù)和生產(chǎn)部門之間的相互尊重與合作 Control Total Productive Maintenance (TPM)38 Benefits of TPM uPromotes operator involvement uRestores equipment to a higher performance level uUncover and eliminate premature equipment failures uReduce total manufacturing costs uReduces waste uBuilds a sense of pride in maintaining the equipment uPromotes cooperation and respect between maintenance and production Control Total Productive Maintenance (TPM)39 職責(zé)范圍 u精益6Sigma團隊 u倡導(dǎo)者/發(fā)起人 uTPM團隊 n操作員 n現(xiàn)場主管 n維護(hù)人員 Control Total Productive Maintenance (TPM)40 Areas of Responsibility uLean Six Sigma Team uChampion/Sponsor uTPM Team nOperator nSupervisor nMaintenance Control Total Productive Maintenance (TPM)41 精益6Sigma團隊的任務(wù) u確定一個TPM項目的需求 u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) u與操作員進(jìn)行深入溝通以了解他們的期望 Control Total Productive Maintenance (TPM)42 Lean Six Sigma Team Role uDetermine the need for a TPM Project uGather history of maintenance cost, delay, machine availability, and quality problems uInterview Operators to get their prospective Control Total Productive Maintenance (TPM)43 u現(xiàn)場活動 n組成TPM團隊 l負(fù)責(zé)設(shè)備維護(hù)的人員 l操作員 l一線管理人員 n準(zhǔn)備必要的裝備 n幫助TPM團隊診斷異常 n協(xié)助跨功能培訓(xùn) n收集整理故障標(biāo)牌的拷貝并生成工作明細(xì)表 n提供人力資源方面的支持 精益6Sigma團隊的任務(wù) Control Total Productive Maintenance (TPM)44 Lean Six Sigma Team Role uOn floor activities nAssemble the TPM Team lMaintenance personnel lOperators lFirst line supervision nProvide necessary equipment nHelp team diagnose abnormalities nAssist skilled trades nCollect copies of defect tags and generate a work list nProvide people resources Control Total Productive Maintenance (TPM)45 倡導(dǎo)者/發(fā)起人的角色 u一旦完成現(xiàn)場工作,接下來將: n形成工作任務(wù)并跟蹤其完成情況 n協(xié)助建立和引入正確的定期維護(hù)明細(xì)表 n協(xié)助維持改善結(jié)果 n評估設(shè)備綜合利用率OEE n展示TPM的改善的成就 Control Total Productive Maintenance (TPM)46 Champion/Sponsor Role uUpon Completion of On Floor Event nGenerate and track completion of work orders nAssist in creation and posting of accurate Periodic Maintenance List nAssist in sustaining the gains nEvaluate Overall Equipment Effectiveness nDisplay TPM improvements Control Total Productive Maintenance (TPM)47 現(xiàn)場主管的角色 u指導(dǎo)并推廣TPM概念 u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 u激發(fā)操作員的主人翁意識 u對操作員授權(quán) u為TPM活動提供時間方面的準(zhǔn)備 u促進(jìn)生產(chǎn)與維護(hù)雙方的合作 Control Total Productive Maintenance (TPM)48 Supervisors Role uCoach and promote TPM Concepts uMonitor ongoing housekeeping and machine cleanliness uPromote Operator ownership uEmpower Operators uProvide time for TPM activities uPromote cooperation between Production and Maintenance Control Total Productive Maintenance (TPM)49 維護(hù)人員的角色 “專業(yè)的管理者” u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; u使用振動分析,磨損度分析,熱感應(yīng)等預(yù)測工具; u建立維護(hù)設(shè)備的保養(yǎng)記錄 u與操作員協(xié)同工作并提供技術(shù)支持 u執(zhí)行設(shè)備大修,綜合調(diào)試 u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) u促進(jìn)TPM Control Total Productive Maintenance (TPM)50 Maintenance Role “The Specialized Caretakers” uPerform all planned preventative maintenance and take corrective action as needed uUse predictive tools such as vibration analysis, wear particle analysis, and thermography uDocument equipment maintenance history uCooperate with Operators and provide technical assistance uPerform equipment overhaul, complex adjustments uProvide special skill tasks, high safety risk tasks uPromote TPM Control Total Productive Maintenance (TPM)51 操作員角色 “一線管理者” u清潔和缺陷檢查 u執(zhí)行基本的潤滑,多點檢測的工作 u按照核準(zhǔn)清單的項目進(jìn)行定期保養(yǎng) u按計劃執(zhí)行日常清潔和整理 u識別剛剛發(fā)生的設(shè)備異常 u根據(jù)需要協(xié)助維護(hù)人員進(jìn)行維修 u執(zhí)行基本的調(diào)試工作 u改善提案 u促進(jìn)TPM Control Total Productive Maintenance (TPM)52 Operators Role “The First Line Caretaker” uClean and inspect for defects uPerform basic lubrication, multi-point inspection uPerform Periodic Maintenance per approved List uPerform routine cleaning and housekeeping as scheduled uIdentify equipment defects as they arise uAssist Maintenance with repairs upon request uPerform basic adjustments uSuggest improvements uPromote TPM Control Total Productive Maintenance (TPM)53 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 Control Total Productive Maintenance (TPM)54 The 7 Steps of Total Productive Maintenance 1. Perform initial machine cleaning and inspection 2. Identify and tag machine defects and leaks 3. Develop Operator and Maintenance PMs 4. Instruct Operators in proper PM techniques 5. Instruct Maintenance Staff in proper PM techniques 6. Implement 5S Housekeeping and Organization 7. Monitor OEE and encourage cooperation Control Total Productive Maintenance (TPM)55 TPM 安全常識 u遵守/使用 n停工現(xiàn)場標(biāo)牌警示程序 n正確的起重方法 n用電安全操作規(guī)范 n勞保裝備 l手套 l工作鞋 l護(hù)目鏡 l防塵口罩 l耳塞 Control Total Productive Maintenance (TPM)56 TPM Safety Habits uFollow/Use nLockout Tagout Procedure nProper Lifting Techniques nElectrical Safety Guidelines nPersonal Protective Equipment lGloves lSafety Shoes lGoggles lRespirators lHearing Protection Control Total Productive Maintenance (TPM)57 TPM 步驟1 初始的機器清潔和檢查 u目的:識別需修理處并標(biāo)示缺陷 u執(zhí)行: n徹底清潔機器-團隊所有成員參與 n并將所有需要維修的項目標(biāo)示并記錄 Control Total Productive Maintenance (TPM)58 TPM Step 1 Initial Machine Inspection uPurpose: To Identify needed repairs and tag defects uExecution: nClean machine thoroughly done by all team members nTag and record all repairs needed in a project notebook Control Total Productive Maintenance (TPM)59 TPM 步驟1 “現(xiàn)場活動” u徹底的清潔工作包括: n清除所有的碎屑及其他殘余物 n徹底地去除油污 n調(diào)節(jié)壓縮空氣 n更換過濾器,潤滑劑等 n潤滑移動部件及接頭處 n清理不必要的使用工具,五金器具及備件等 u“你的雙手肯定會臟兮兮的!” Control Total Productive Maintenance (TPM)60 TPM Step 1 “On Floor Activities” uA Thorough Cleaning Includes: nRemoving all chips and other debris nThorough Degreasing nCompressed air for controls nChanging filters, lubricants, etc. nLubricating moving parts and joints nRemoving unnecessary tooling, hardware, supplies, etc. u“You have to get your hands dirty!” Control Total Productive Maintenance (TPM)61 TPM 步驟1 “現(xiàn)場活動” u維修項標(biāo)示色碼 u標(biāo)簽上須標(biāo)示的信息: n機器的資產(chǎn)編號 n機器位置及故障位置 n投入使用的日期及使用人 n機油泄漏橙色 n冷卻液泄漏綠色 n空氣泄漏 黃色 n機器故障 粉紅色 n電氣問題-藍(lán)色 Control Total Productive Maintenance (TPM)62 TPM Step 1 “On Floor Activities” uRepair Tag Color Codes uInformation Needed on Tags nAsset number of machine nLocation and relative position of defect on machine nName of originator and date nOil Leaks - Orange nCoolant Leaks - Green nAir Leaks - Yellow nMachine Defects - Pink nElectrical Problems - Blue Control Total Productive Maintenance (TPM)63 關(guān)注TPM清潔效果 降低停機時間70% u之前 砂粒及碎屑很嚴(yán)重 n無法調(diào)試 n運行速度降低 n故障接連發(fā)生 u之后 跨功能工作的成果 n更換缺損的零部件 n調(diào)試校正 n恢復(fù)至設(shè)計速度且保持品質(zhì) Control Total Productive Maintenance (TPM)64 Focused TPM Cleaning Effort Reduced Downtime by 70% uBefore Severe Grit and Chips nOut of adjustments nRunning at reduced speeds nConstant breakdowns uAfter Cross-functional Effort nReplaced broken and missing parts nCorrected the adjustment nReturned to designed speed without incurring scrap Control Total Productive Maintenance (TPM)65 TPM 步驟2 修復(fù)機器的缺漏 u目的:修復(fù)在步驟1中找到的缺漏項目 u注意事項: n倡導(dǎo)者/發(fā)起人需確保標(biāo)示出的問題得到修復(fù) n實際的修復(fù)工作不必一定由團隊成員來做; n生產(chǎn)主管須確保機器能夠使用 Control Total Productive Maintenance (TPM)66 TPM Step 2 Repair machine defects and leaks uPurpose: To repair items found in Step 1 uConsiderations: nChampion/Sponsor insures tagged problems are repaired nActual repairs do not have to be done by team members nProduction Supervisor has to make machine available Control Total Productive Maintenance (TPM)67 TPM 步驟2 u消除故障因素 n固定并擰緊所有的扣件,接頭,螺釘及螺母 n替換任何缺損的部件 n替換任何損壞,磨損及規(guī)格不符的零部件 n解決所有的滲漏,溢出,噴濺,噪雜等問題 u提高如下環(huán)節(jié)的可操作性: n清潔 n潤滑 n調(diào)試 n檢查/測試 Control Total Productive Maintenance (TPM)68 TPM Step 2 uEliminate factors contributing to failure: nSecure and tighten all fasteners, fittings, bolts and screws nReplace any missing parts nReplace any damaged, worn or wrong size parts nResolve all causes of leaks, spillage, spray and splatter uImprove accessibility in order to accomplish: nCleaning nLubricating nAdjusting nChecking/inspecting Control Total Productive Maintenance (TPM)69 TPM 步驟3 建立操作員和維護(hù)人員合作的PM計劃 u確保發(fā)出完善的定期檢測的查檢表 目的: u注意事項: n由TPM項目小組建立PM計劃 n誰來執(zhí)行任務(wù) n任務(wù)執(zhí)行的頻率 (例如每天,每周等) Cont