精益生產(chǎn)之全面生產(chǎn)維護(hù)TPM(中英文版)2332273

1、MeasureAnalyzeControlImproveLean Six Sigma全面生產(chǎn)維護(hù) (TPM)uTPMuTPM 團(tuán)隊組織u設(shè)備綜合利用率OEE uTPM 活動步驟RD011202MeasureAnalyzeControlImproveLean Six SigmaTotal Productive Maintenance (TPM)uTPMuTPM Team OrganizationuOverall Equipment Effectiveness uTPM PhasesRD011202Control精益6 過程改善流程分析分析控制控制改進(jìn)改進(jìn)定義定義選定題目列出客戶從顧客之聲中列出關(guān)

2、建需求定出項目焦點和重要指標(biāo)完成 PDF測量測量繪制業(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(jī)會根本原因排序?qū)ふ腋驹蜥槍﹃P(guān)鍵因子改進(jìn)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(jī)會測量測量定義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&a

3、mp;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Revised 1-12-023ControlLean Six Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of th

4、e CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of

5、Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process Me

6、tricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureDefineProject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstorm

7、ingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp & CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAff

8、inityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-024Control課程目的u學(xué)習(xí)一種方法以便:n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）;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5ControlLe

9、arning ObjectivesuLearn a method to:nIntegrate operational productivity factors applicable in process industries in a single comprehensive measurementnEliminate factors contributing to equipment failurenImprove accessibility for cleaning and maintaining equipmentnUse predictive maintenance as a diag

10、nostic toolnImplement maintenance audits6Control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;7ControlWhats in It for Me?uOptimized process operations and maintenanceuA method to replace the traditional approach of detecting and correcting faulty conditions as

11、 they occuruA proactive system which monitors and corrects causesuAn operations strategy based on understanding the cause and effect system affecting the major contributors to process performance8Control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(jī),和提高作業(yè)與保養(yǎng)協(xié)調(diào)程度的常識性方法。9ControlTotal Productive Maintenance (TP

12、M)TPM DefinitionuA common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance.10ControlTPMu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)11ControlTPMuAchieve zero equipment breakdown

13、s and zero defects through preventionuEstablish prevention bynMaintaining normal conditionsnEarly detection of abnormalitiesnQuick response12Control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13ControlT

14、raditional Approach“Re-Active Maintenance”Maintenance “WE FIX”nPerform all maintenance activitiesnPerform “Fire Fighting” maintenance when a machine breakdown occursnOrder and administer all tooling, supplies, etc.nPerform Preventive MaintenanceManufacturing “WE OPERATE”nGenerally does not perform a

15、ny maintenance activitiesnContacts maintenance when a machine breakdown occursnInactive during maintenance activitiesn“Run it till it breaks”14Control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(jī)測試n熱感應(yīng)n油況分

16、析15ControlKey DefinitionsPreventive 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 SchedulesPredictive Maintenance is a situation b

17、ased method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring.nVibration AnalysisnLaser MeasuringnUltrasoundnGenerator TestingnThermographynOil Analysis16Control現(xiàn)狀分析和團(tuán)隊組織u評估當(dāng)前的操

18、作條件:n機(jī)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(tuán)隊成員的實力u挑選TPM倡導(dǎo)者及團(tuán)隊成員n建立初始的實施專門小組n確定團(tuán)隊目標(biāo)17ControlPresent State Analysisand Team OrganizationuAssess Current Operating ConditionsnMachine utilization, productivity, etc.nMaintenance repair costs (parts and labor)nPrioritize order of TPM effor

19、tsuAssess capabilities of potential TPM Champions and Team MembersuSelect TPM Champion and Team MembersnEstablish initial kick-off workshopnEstablish team goal18Control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19ControlTy

20、pical Operational Process MeasurementsuUtilization: The ratio of equipment actual operating time to the total available operating timen= Actual Operating Time/Available TimeuEfficiency: The ratio of actual product produced to a standardn= (Actual Parts/Hour)/(Standard Part/Hour)uOutput: Measure of o

21、utput over a specified time periodn= lbs/hr, pieces/hr20Control設(shè)備綜合利用率OEEu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.21ControlOverall Equipment EffectivenessuOverall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality product at the designed

22、 rate.22ControlOEE分解:六大浪費故障及輕微故障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(jī)器空轉(zhuǎn)浪費機(jī)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.23ControlOEE Breakdown: The Six Big LossesBreakdowns

23、 and Minor StoppagesMalfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages)SetupAny activity related to equipment changeover, setup, or cleaning.IdlingTime equipment is running but not producing product.Speed LossesEquipment op

24、erating at less than standard or design speed due to equipment/product abnormalityQuality FactorsActivities related to ensuring the quality of the product produced on the equipment (in-process checks).Rework LossesThe time taken to re-process product or time take to produce un-usable product.24Contr

25、ol六大浪費的識別練習(xí)識別損失類別12345678910機(jī)器A在下午1點鐘完成一產(chǎn)品裝配而在下午2:27開始另一產(chǎn)品的裝配工作現(xiàn)象由于電氣故障機(jī)器A的運轉(zhuǎn)中斷31分鐘過程中的質(zhì)量檢查耗時22分鐘機(jī)器B上的小裝置裝卸時間為4分鐘由于機(jī)械故障機(jī)器X運轉(zhuǎn)中斷8分鐘機(jī)器Z的清潔時間為47分鐘工件被軋住造成機(jī)器C中斷3分鐘從取樣到送至實驗室耗時32分鐘機(jī)器Z返修200個工件由于機(jī)油線路泄漏機(jī)器D僅能以每小時加工100片產(chǎn)品的速度運行達(dá)不到125片的標(biāo)準(zhǔn) 25ControlSix Big Losses Identification Exercise SCENARIO LOSS IDENTIFICATION

26、 1. Machine A operation is interrupted by an electrical problem for 31 minutes 2. An in-process quality check takes 22 minutes 3. Load & unload time between widgets on machine B is 4 minutes 4. Machine X operation is interrupted of 8 minutes due to a mechanical problem 5. Cleaning time on machin

27、e Z is 47 minutes 6. Jammed piece causes machine C stoppage of 3 minutes 7. Machine A completes a load at 1:00 pm and begins another load (different product) at 2:27 pm 8. A sample is taken and transported to the lab taking 32 minutes 9. 200 pieces are re-processed on machine Z 10. Machine D runs at

28、 100 pc/hr not 125 pc/hr due to leaky oil lines 26ControlOEE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(jī)器故障及輕微故障, 行政事務(wù)/非作業(yè)時間機(jī)器設(shè)置與調(diào)整速度損失機(jī)器空轉(zhuǎn)返工及報廢 40 - 3.1 - 3.8 - 4.2 = 73%40OEE = 53%AL HRS = 40 - 3.1 - 3.8 -

29、 4.2 = 28.9 hrsOL HRS = 28.9 - 3.1 - 1.1 = 26.3 hrsQL HRS = 26.3 - 3.1 - 2.1 = 21.1 hrs27ControlCalculating OEE ElementsLoading Time (LT)Total Hours Available for Equipment Operation = 40 hrsAvailabilityLevel (AL)OperatingLevel (OL)QualityLevel (QL)OEE73% x 91% x 80% 26.3 - 3.1 - 2.1 = 80%26.3 28.9

30、- 1.5 - 1.1 = 91%28.9QualityFactorsBreakdownsMinor Stops, and Admin.SetupSpeed LossesIdlingRework andScrap 40 - 3.1 - 3.8 - 4.2 = 73%40OEE = 53%AL HRS = 40 - 3.1 - 3.8 - 4.2 = 28.9 hrsOL HRS = 28.9 - 3.1 - 1.1 = 26.3 hrsQL HRS = 26.3 - 3.1 - 2.1 = 21.1 hrs28Control世界級的OEE性能水平承載時間承載時間 (LT)同步計劃運轉(zhuǎn)時間及生產(chǎn)

31、性防護(hù)時間同步計劃運轉(zhuǎn)時間及生產(chǎn)性防護(hù)時間可用水平可用水平 (AL)運行水平運行水平 (OL)質(zhì)量水平質(zhì)量水平 (QL)OEE90% x 95% x 99%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)返工及報廢OEE = 85% 是世界級的性能水平AL始終保持在始終保持在 90%以上以上OL維持在維持在 95%以上以上QL不低于不低于 99%29ControlWorld Class OEE PerformanceLoading Time (LT)Operation Time and PM Time is scheduled synchronizing the

32、 twoAvailabilityLevel (AL)OperatingLevel (OL)QualityLevel (QL)OEE90% x 95% x 99%QualityFactorsBreakdownsMinor Stops, and Admin.SetupSpeed LossesIdlingReworkand ScrapOEE = 85% is World Class PerformanceThe AL is consistently kept at or above 90%The OL is maintained at or above 95%The QL is at or abov

33、e 99%30Control階段階段 I階段階段 II階段階段 III階段階段 IVTPM 階段31ControlPHASE IPHASE IIPHASE IIIPHASE IVTPM Phases32Control六大團(tuán)隊活動1. 通過小規(guī)模的小組活動來提高機(jī)器的正常運行時間,消除造成停工的主要根源:n機(jī)器的啟動損失n機(jī)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(jī)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). 33ControlSix Team Activities1. Use small group activities to improve machine up

34、time by eliminating the major sources of downtime.nStartup LossesnBreakdown LossesnMaterial and Scheduling Losses2. Involve the machine operators as well as skilled trades in basic preventative maintenance such as lubrication, cleaning, and inspection for defects. 34Control六大團(tuán)隊活動(續(xù)上頁)3. 使用諸如振動分析類的預(yù)測

35、工具擯棄過去那種反應(yīng)式的維護(hù)模式4. 增強(qiáng)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(jī)待料;6. 規(guī)劃人員配備以確保瓶頸設(shè)備處的滿員運作35ControlSix Team Activities (Cont.)3. Utilize predictive tools such as vibration analysis to move past reactive type maintenance4. Increase awareness and knowledge of equipment to improve produc

36、tivity and reduce downtime5. 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 staffed36ControlTPM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

37、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 37ControlBenefits of TPMuPromotes operator involvementuRestores equipment to a higher performance leveluUncover and eliminate premature equipment failuresuReduce total manufacturing costsuReduces waste uBuilds a sense of pride in maintaining the equipmentuPromot

38、es cooperation and respect between maintenance and production 38Control職責(zé)范圍u精益6Sigma團(tuán)隊u倡導(dǎo)者/發(fā)起人uTPM團(tuán)隊n操作員n現(xiàn)場主管n維護(hù)人員39ControlAreas of ResponsibilityuLean Six Sigma TeamuChampion/SponsoruTPM TeamnOperatornSupervisornMaintenance40Control精益6Sigma團(tuán)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

39、員進(jìn)行深入溝通以了解他們的期望41ControlLean Six Sigma Team RoleuDetermine the need for a TPM ProjectuGather history of maintenance cost, delay, machine availability, and quality problemsuInterview Operators to get their prospective42Controlu現(xiàn)場活動n組成TPM團(tuán)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(tuán)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

40、生成工作明細(xì)表n提供人力資源方面的支持精益6Sigma團(tuán)隊的任務(wù)43ControlLean Six Sigma Team RoleuOn floor activitiesnAssemble the TPM TeamlMaintenance personnellOperatorslFirst line supervisionnProvide necessary equipmentnHelp team diagnose abnormalitiesnAssist skilled tradesnCollect copies of defect tags and generate a work list

41、nProvide people resources44Control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OEEn展示TPM的改善的成就45ControlChampion/Sponsor RoleuUpon Completion of On Floor EventnGenerate and track completion of work ordersnAssist in creation and posting of accurate Periodic Maintenance

42、List nAssist in sustaining the gainsnEvaluate Overall Equipment EffectivenessnDisplay TPM improvements46Control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(jī)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47ControlSupervisors RoleuCoach and promote TPM ConceptsuMonitor ongoing housekeeping and machine cl

43、eanlinessuPromote Operator ownershipuEmpower Operators uProvide time for TPM activitiesuPromote cooperation between Production and Maintenance48Control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)TPM49ControlMainte

44、nance Role“The Specialized Caretakers”uPerform all planned preventative maintenance and take corrective action as neededuUse predictive tools such as vibration analysis, wear particle analysis, and thermographyuDocument equipment maintenance historyuCooperate with Operators and provide technical ass

45、istanceuPerform equipment overhaul, complex adjustmentsuProvide special skill tasks, high safety risk tasksuPromote TPM 50Control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)TPM51ControlOperators Role“The First Line Caretaker”uClean an

46、d inspect for defectsuPerform basic lubrication, multi-point inspectionuPerform Periodic Maintenance per approved ListuPerform routine cleaning and housekeeping as scheduleduIdentify equipment defects as they ariseuAssist Maintenance with repairs upon requestuPerform basic adjustmentsuSuggest improv

47、ementsuPromote TPM 52Control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53ControlThe 7 Steps of Total Productive Maintenance1. Perform initial machine cleaning and inspection2. Identify and tag machine defects a

48、nd leaks3. Develop Operator and Maintenance PMs4. Instruct Operators in proper PM techniques5. Instruct Maintenance Staff in proper PM techniques6. Implement 5S Housekeeping and Organization7. Monitor OEE and encourage cooperation54ControlTPM 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

49、塵口罩 l耳塞55ControlTPM Safety HabitsuFollow/UsenLockout Tagout ProcedurenProper Lifting TechniquesnElectrical Safety GuidelinesnPersonal Protective EquipmentlGloveslSafety Shoes lGoggleslRespirators lHearing Protection56ControlTPM 步驟1初始的機(jī)器清潔和檢查初始的機(jī)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(jī)器-團(tuán)隊所有成員參與n并將所有需要維修的項目標(biāo)示

50、并記錄57ControlTPM Step 1Initial Machine InspectionuPurpose: To Identify needed repairs and tag defectsuExecution:nClean machine thoroughly done by all team membersnTag and record all repairs needed in a project notebook58ControlTPM 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

51、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!”59ControlTPM Step 1“On Floor Activities”uA Thorough Cleaning Includes:nRemoving all chips and other debrisnThorough DegreasingnCompressed air for controlsnChanging filters, lubricants, etc.nLubricating moving parts and jointsnRemoving unnecessary tooling, hardware

52、, supplies, etc.u“You have to get your hands dirty!”60ControlTPM 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(jī)器的資產(chǎn)編號n機(jī)器位置及故障位置n投入使用的日期及使用人n機(jī)油機(jī)油泄漏泄漏橙色橙色n冷卻液泄漏冷卻液泄漏綠色綠色n空氣泄漏空氣泄漏 黃色黃色n機(jī)器故障機(jī)器故障 粉紅色粉紅色n電氣問題電氣問題-藍(lán)色藍(lán)色61ControlTPM Step 1“On Floor Activities”uRepair Tag Color Codes uInformation Needed on TagsnAsset number

53、 of machinenLocation and relative position of defect on machinenName of originator and datenOil Leaks - OrangenCoolant Leaks - GreennAir Leaks - YellownMachine Defects - PinknElectrical Problems - Blue62Control關(guān)注TPM清潔效果 降低停機(jī)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)

54、63ControlFocused TPM Cleaning Effort Reduced Downtime by 70%uBefore Severe Grit and ChipsnOut of adjustmentsnRunning at reduced speedsnConstant breakdownsuAfter Cross-functional EffortnReplaced broken and missing partsnCorrected the adjustmentnReturned to designed speed without incurring scrap64Cont

55、rolTPM 步驟2修復(fù)機(jī)器的缺漏修復(fù)機(jī)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(tuán)隊成員來做;n生產(chǎn)主管須確保機(jī)器能夠使用65ControlTPM Step 2Repair machine defects and leaksuPurpose: To repair items found in Step 1uConsiderations:nChampion/Sponsor insures tagged problems are repairednActual repairs do not have to be d

56、one by team membersnProduction Supervisor has to make machine available66ControlTPM 步驟2u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67ControlTPM Step 2uEliminate factors contributing to failure:nSecure and tighten all fasteners, fittings, bo

57、lts and screwsnReplace any missing partsnReplace any damaged, worn or wrong size partsnResolve all causes of leaks, spillage, spray and splatteruImprove accessibility in order to accomplish:nCleaningnLubricatingnAdjustingnChecking/inspecting 68ControlTPM 步驟3建立操作員和維護(hù)人員合作的建立操作員和維護(hù)人員合作的PM計劃計劃u確保發(fā)出完善的定期

58、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)69ControlTPM Step 3Develop Operator PMs and Maintenance PMsuPurpose: To insure adequate preventative maintenance checklists are posteduConsiderations:nTPM Project Team to develop PMsnWho is to perform tasksnFrequency of tasks (i.e., daily, week

59、ly, etc.)70ControlTPM 步驟4由操作員執(zhí)行的由操作員執(zhí)行的PM作業(yè)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u注意事項:n操作員負(fù)責(zé)按照管理文件執(zhí)行PM工作;n生產(chǎn)主管須確保PM工作的有效實施71ControlTPM Step 4PM activity performed by the OperatoruPurpose: To detect early problems, provide the service interval, and insure 5S procedure is followeduConsiderations:nOperator is resp

60、onsible to perform PMs as documentednProduction Supervisor to insure PMs are effective72ControlTPMuTPM使操作員更加獨立地自我管理和控制;u操作員時時關(guān)注小問題的發(fā)生就有可能: n迅速地發(fā)現(xiàn)潛在的問題n修正現(xiàn)有問題n確定狀態(tài)正常n良好地維持設(shè)備整體狀況73ControlTPMuTPM makes the operator more independentuThe operator sees the small problems now with the possibility of: nQuickly noting potential problem