TPM培训资料会员生产培养培训资料PPT.ppt

全员生产保养totalproductivemaintenance,目录tableofcontents,tpm概略tpmoverviewtpm目的theaimoftpmtpm流程tpmprocess自主保养autonomousmaintenance计划保养plannedmaintenance预防工程preventiveengineering教育与行动education&practice保证质量insuredqualitytpm改善活动tpmkaizenactivitiestpm活动进阶advancedtpmactivities,tpm概略tpmoverview,何谓tpmwhatistpm,全员生产保养是这样一个系统totalproductivemaintenanceisasystemthat涉及工场/维修人员involvesbothshopfloorassociatesandmaintenanceassociates支持精益西格玛流程supportstheleansigmaprocess保持设备最佳状态keepsequipmentinoptimalcondition,为何要实施tpm？whyimplementtpm?,忽视设备基本状况basicequipmentconditionsneglected操作维修技能欠佳insufficientoperatingandmaintenanceskills设备设计固有不足inherentweaknessinequipmentdesign设备恶化无人监督overlookeddeterioration没有遵守使用要求usageconditionsnotobserved,宏观愿景macrovision,tpm世界性的公司worldwidecompany,工人自主保养operatorautonomousmaintenance,预防保养preventivemaintenance,经理支持功能managersupportfunction,工程设备设计改善eng.equip.designimprovement,品质改善qualityimprovement,全员生产保养tpm,高级管理层领导sml,生产准备2p,西格玛改善sigmakaizen,tpm目标tpmgoals,零故障zerobreakdowns零缺陷zerodefects零事故zeroaccidents全员参与totalemployeeinvolvement提高机器效率,满足节拍速度achievetaktrateatthehighestmachineeffectiveness,tpm与精益西格玛流程tpmandleansigmaprocess,fle,及时生产justintime,自働化jidoka,均衡生产productionsmoothing,机器可靠machinereliability机器高效machineeffectiveness联动操作linkedoperations人力利用laborutilization,制程能力processcapability最佳机况optimalmachineconditions制程重复processrepeatability防错装置mistakeproofing,实现流畅生产,必须实行tpmtpmisessentialwhenflowproductionisachieved,tpm与传统保养tpmvs.traditionalmaintenance,每班8小时8hrshift,有效时间=7小时40分effectiveness=7hrs40min,工人开会:10分钟operatormeeting,10min,10min,设备清洁与润滑:10分钟equipmentcleaning&lubrication,传统生产班次traditionaloperatingshift:,实行tpm的班次tpmshift:,本班开始shiftstart,品质问题quality,暂停minorstoppages,故障停机breakdown,调整adjustment,本班结束shiftend,每班8小时8hrshift,有效时间=6小时effectiveness=6hrs,整体设备效率overallequipmenteffectiveness,故障停机breakdowns换模set-ups调整adjustments,空闲idling暂停minorstops速度降低reducedspeed,不良品defects返工rework启动start-up合格率损失yieldloss,availability=,performance=,quality=,availabletimedowntimeavailabletime,mctx#partsproducedoperatingtime,#ofpartsproduceddefects/rework#ofpartsproduced,六个主要损失sixmajorlosses,整体设备效率%=可用效率x性能效率x品质效率x100%oee(%)=availabilityxperformancexqualityx100%,discretemfg.,processind.,availabletimedowntimeavailabletime,amountproducedstd/hrxoperatingtime(hrs),amountdefect/reworktotalamountproduced,可用效率,性能效率,质量效率,可用时间停机时间,可用时间,操作时间,机器周期时间x已生产零件数,已生产零件数不良品数/返工数,已生产零件数,离散式生产,流程工业,可用时间停机时间,可用时间,标准产值/小时x操作时间,已生产产值,总产值不良品/返工产值,已生产总产值,equipmentutilization(availability)(whendoyouplantorunit?),maximumpossibleproduction=1440minutes(24hours),planneddowntime,no3rdshift=420min.lunch(2shifts)=60min.dept.meetings=20min.planneddowntime=500min.,thisiswhereoeestarts!,maxpossibleproduct1440min.planneddowntime-500min.scheduledproduction=940min.,maxpossibleproduction,scheduledproduction,availabilitycanyourunitwhenitsscheduled?,940min.scheduledproduction,-150min.setup,790min.,-140min.breakdowns,650min.,performanceefficiencyhowfastdoyourunwhenyourun?,650min.185min.minorstoppages,-40min.speedloss,-,465min.,=425min.actualproduction,rateofqualityhowmuchofwhatyoumakeisthecustomerhappywith?,425min.actualproduction-51min.timeusedmanufacturingdefectiveparts,374min.goodproduct,overallequipmenteffectiveness,=39.8%,oee=,量度指标metrics,整体设备效率overallequipmenteffectiveness(oee)可用效率availability性能效率performance品质效率quality,保养效率maintenanceeffectiveness平均故障时间间隔mttf(meantimetofailure)平均无故障时间mtbf(meantimebetweenfailure)平均维修时间mttr(meantimetorepair),可靠性reliability,mttf=平均故障时间间隔:上次故障至本次故障之时间meantimetofailure(thetimefromthepreviousbreakdowntothecurrentbreakdownofmachine.mtbf=平均无故障时间:从开机到故障停机之时间meantimebetweenfailure(theelapsetimefromthestartupofthemachinetothecurrentbreakdownofthemachinemttr=平均维修时间:从上次故障停机到重新开机之时间thetimefromthepreviousbreakdowntostartupofthemachine.保养效率由mtbf及mttf来衡量,比例越高,机况越好!maintenanceeffectivenessismeasuredbymtbf/mttfthegreaterthepercentagethebetter!,tpm的目的：theaimoftpm:,改善设备运行状况toimprovetheequipmentoperatingcondition维持设备最佳性能与可靠性tosustainequipmentatanoptimallevelofperformance&reliability延长设备使用寿命tolengthenthelifeexpectancyofequipment,tpm流程tpmprocess,tpm五大支柱the5pillarsoftpm,自主保养autonomousmaintenance,计划保养planningmaintenance,预防工程preventiveengineering,品质quality,教育与行动education&practice,实施tpm十步骤tpmimplementation-10steps,1.测量工作单元上所有自动设备之oeemeasureoeeforallautomaticequipmentincells.2.测量各工作单元的节拍时间measuretaktrateperformanceforeacharea.3.将单元节拍时间与设备oee进行比较correlatecelltaktrateperformancetoequipmentoee.4.选择特定机器作为改善重点selectspecificmachineforkaizenfocus.5.根据oee六大损失制定改善目标establishimprovementgoalrelatedtothesixmajorlossesofoee.6.选定设备改善专职队员selectpermanentequipmentimprovementteammembers.7.发动工人进行自主保养及计划保养活动initiateoperatorautonomousmaintenanceandplannedmaintenanceprograms.8.继续更新检查单,培训工人,保证机器最佳状况continuetoupdatechecklists,trainoperators,andpursueoptimalmachineconditions.9.为选定设备设立tpm活动之目视表现板establishvisualperformanceboardsfortpmactivitiesonselectedequipment.10.每月将改善目标与实际结果进行比较。评价是否需要进行更多改善活动,制定更高的目标,或需要更换专职队员checkresultstoimprovementgoalsmonthly.evaluateneedforadditionalkaizenactivity,settingmoreaggressivegoals,ormodifyingpermanentteammembers.,自主保养autonomousmaintenance,自主保养autonomousmaintenance,工人要学习asystemwhereequipmentoperatorslearnto:进行每日检查performdailychecks按需润滑设备lubricateequipmentasneeded更换简单零件replacesimplecomponents进行机器小修performminorrepairsonmachines帮助解决问题assistinproblemsolving,工人是机器发生异常的早期预警系统operatorsbecometheearlywarningsystemformachineabnormalities,自主保养五步法5stepstoautonomousmaintenance,1.进行基本清洁活动performbasiccleaning2.根除肮脏污染源头eliminatesourcesofdirtandcontamination3.建立清洁润滑标准establishcleaningandlubricationstandards4.教会设备基本检查,进行自主设备检查teachgeneralinspectionofequipmentandperformautonomousequipmentinspection5.培养整齐有序习惯instillorderlinessandorganization,工人作用rolesofoperators,预防污染preventdeterioration:维持基本条件maintainingbasicconditions正确操作设备operatingequipmentcorrectly判断污染measuredeterioration:进行检查inspecting制定标准,坚持执行developingandadheringtostandards,纠正污染correctdeterioration:报告问题reportingproblems协助维修assistinginrepairs进行微调(按本地合约)makingminoradjustments(perlocalcontract)加入团队participateinteams:工作中心团队workcenterteams解决问题团队problem-solvingteams,维修人员作用rolesofmaintenancepersonnel,设备保养maintainequipment检验(拆卸)inspect(disassembly)计划保养plannedoverhauls预防保养preventivemaintenance教导工人学会特定保养工作teachselectedmaintenancetaskstooperators,设备改善improveequipment支持可靠性及可维修性改善supportr&mimprovement实施预测技术implementpredictivetechnologies纠正设计不足correctdesignweaknesses搞好供方合作partnerwithvendors,设备检查表equipmentinspectionchecklist,初步清洁initialcleaning螺母、螺栓等有无松动、摇摆、遗失?anynuts,bolts,etc.loose,wobblyormissing?活动零件、夹具安装有无窜动?anyplayinmovingpartsorfixturemountingsection?机器内部有无多余零件?anyunnecessaryitemslocatedonthebodyofthemachine?润滑系统lubrication润滑油是否到达滑动部件?doesoilreachslidingparts?润脂嘴、机油盖等是否损坏、遗失?anydamagedormissinggreasenipples,oilcaps,etc.?供油装置、管路、接头有无漏油?anyoilorgreaseleaksfromsupplydevices,pipes,fittings?加油工人有无内外清洁?areoilerscleaninsideorout?油标是否容易看见?istheoilleveleasilyvisible?,设备检查表equipmentinspectionchecklist,液压系统hydraulics油箱装够油了吗?istheoiltankfilledtothespecifiedlevel?油泵发出异常噪音吗?isthepumpemittinganyabnormalnoises?卸荷阀、减压阀、节流阀防松螺母上紧了吗?arelocknutstightonrelief,reducingandthrottlevalves?卸荷阀、控制装置运作正常吗?arereliefvalvesandcontrolsoperatingcorrectly?高压管路连接变形或磨损了吗?anystrainorwearinhighpressurehoseconnections?电气系统electrical行程开关杠杆能够完全接触吗?dolimitswitchbarsstrikefully?信号灯、指示灯遗失或烧坏了吗?anymissingorburnedoutpilotorindicatorlights?配电盘、电器箱有无线路图?aretherewiringdiagramsinthecontrolpanelsorelectricalboxes?有无多余的、损坏的、压坏的电线或软管?anyunnecessary,damagedordentedwiresorflexibletubing?,设备检查表equipmentinspectionchecklist,传动系统powertransferdevicesv型皮带碰到带轮槽底了吗?dov-beltshitthebottomofpulleygrooves?皮带有无损坏、爆裂、破裂?anydamage,crackingorsplittingofthebelts?滚柱链条的销轴与轴承之间有无足够润滑油?istheresufficientlubricationbetweenpinsandbushingsofrollerchains?转轴有无过热、振动、噪音?anyshaftoverheating,vibrationornoise?联接系统有无锁键、夹紧螺栓松动造成的窜动?anyplayduetoloosekeysorclampingboltsoncouplings?齿轮机构有无过量的躁音、发热、振动?anyexcessnoise,heatorvibrationingearmechanisms?,设备检查表equipmentinspectionchecklist,螺母螺栓nutsandbolts登记记号允许松紧度检查吗?doregistrationmarkspermittightnesschecks?螺母螺栓型号及尺寸正确吗?arenutsandboltsofthesuitabletypesorsizesused?垫片尺寸正确,且类型相配吗?arewashersofpropersize,andaretheyconsistentlyused?螺栓有从螺母凸出23圈螺纹吗?doboltsprotrude23threadsfromthenuts?气动系统pneumatics截止阀及球阀漏气吗?anystopvalve,ballvalveleaks?有坏了或多余的手把吗?anybrokenorunnecessaryhandles?已关闭的阀仍有气流吗?doesanyairflowthroughclosedvalves?有任何不必要的装置或喉管吗?areanyunnecessarydevices,hosesorpipespresent?所有喉管都整齐及易于识别吗?arepipesandhosesorderlyandreadilyidentifiable?压力表指示的都是正确设定的压力吗?dopressuregaugesclearlyindicatethecorrectsetpressure?,进行基本清洁performbasiccleaning,做好清洁检查cleantoinspect暴露隐藏不足exposehiddendefects找出脏污源头determinesourceofcontamination识别难于清洁之处identifyhardtoreachareas准备蓝色标签工作prepareforbluetagexercise,消灭脏污源头eliminatesourcesofdirt&contamination,脏污原因causesofcontamination:发生液体泄漏fluidleaks碎片容器很差poorchipcontainment工作不佳poor5spractices工作区有溅洒workareaspills过滤性能不好poorfiltration没有清洁标准nocleaningstandards无工作自豪感poorworkpride环境问题恶劣environment,建立清洁与润滑标准establishcleaning&lubricationstandards,从工人开始进行基本的清洁、检查及润滑活动beginbasicoperatorcleaning,inspectingandlubricatingactivities制定临时标准establishprovisionalstandards进行重点训示createonepointlesson确定活动频次establishfrequencyofactivities月检、周检、日检清单monthly,weeklyanddailychecklist制做检查表developchecklist,重点训示one-pointlesson,进行自主保养检查performautonomousmaintenanceinspection,制定详细的培训计划developindepthtrainingprogram对工人就以下内容进行培训：trainoperatorsin:润滑作用/粘性分析lubrication/viscosityanalysis气动系统pneumatics液压系统hydraulic电气系统electricalsystems驱动系统drivesystems修改目前的重点训示,加入检验检查工作reviseexistingone-pointlessonstoincludeinspectionchecks,培养工场整洁条理思想instillorderliness&organization,工场管理与控制workplacemanagement&control扩展团队活动,做好设备以外的整洁工作expandteamactivitiesbeyondequipmenttootheraspectsoftheprocess搞好工场整洁,实行目视控制，发现改善机会(第4、5个s)exposeopportunitiesforimprovedorganization,orderlinessandvisualcontrol(4th&5ths)进行5s评审perform5saudits,整洁与条理organization&orderliness,目视控制visualcontrols,写出已做的活动,展示取得的进步describesactivitiesundertakenandshowsprogress对比制定的标准,量化取得的改善故障停机、维修呼叫、停线时间等quantifiestheimprovementsmadeagainstagreedmetrics.e.g.(breakdowns,defects,maintenancecall-outs,linedown-time,etc.)细化实际的改善detailstheactualimprovementsmade记录待研究项目recordsissuestobereviewed:没有答复的问题unansweredquestions需要支援的问题complexissuessupportrequired,问题公报problemnewspaper,问题公报problemnewspaper,生产保养完成率pmcompletionratio,保养小组目视控制maintenancegroupvisualcontrol,活动布告板activityboard,自主保养,全员生产保养活动tpmactivities,进行tpm基础知识培训，评审准备工作trainintpmfundamentals&reviewpre-work,实施蓝色标签方法conductbluetagexercise异常情况排序rankabnormalities异常情况维修repairabnormalities,设备oem手册评审reviewequipmentoemmanuals确定工人自主保养路线,制定检查表createop.amroute&checksheet,定义/实施标准化工作define&implementstdwork实现保养反馈循环implementfeedbacklooptomaintenance进行oee表现公告implementoeeperformanceboard,初步活动自主保养initialeventsautonomousmaintenance,tpm的活动tpmactivities,改善前活动(专职队员)pre-kaizenactivity(permanentteam),收集改善活动一个月前的停机数据collectdowntimedataforonemonthpriortoevent进行设备基本清洁活动conductinitialcleaningofequipment收集设备规格、oem手册、机器bom及图纸gathermachinespecifications,oemmanuals,machinebom,blueprints,改善活动(改善团队成员)kaizenactivity(kaizenteam),进行两小时的观察conducttwo-hourobservation清洁脏污源头,贴上蓝色标签cleanandbluetagsourcesofdirtandcontamination集思广益按实施难易程度排序brainstormideasprioritizeaccordingtoimplementationease实施解决方案,消除脏污源头implementsolutionstoeliminatesourcesofcontamination设计工人自主保养路线、检查表及重点训示,实现保养标准化standardizeanddevelopoperatorautonomousmaintenanceroutes,checksheetsandone-pointlesson实行oee表现公告制度implementoeeperformanceboard实施设备保养反馈循环implementequipmentmaintenancefeedbackloop,清洁检查cleantoinspect,改善前before改善后after,蓝色标签流程bluetagprocess,识别脏污及异常源头identifysourcesofcontaminationandmalfunctions每个源头贴上蓝色标签writeabluetagforeachidentifieditem在机器上靠近源头处挂上蓝色标签attachbluetagtomachineatlocationofspecificitem在总表上记录蓝色标签资料documenttaginformationonsummarychart与保养人员评审蓝色标签,按影响程度及修理难易程度排序reviewtagswithmaintenancepersonnelasateam&rankaccordingtoimpact&difficultyofrepair改善活动期间没有解决的异常问题,保养人员要做好行动计划,列明负责人及时间要求maintenancecompleteswhoandwheninformationforabnormalitiesnotrepairedduringkaizeneventandcreatesactionplan改善小组更新总表状态teamupdatesstatusofsummarychart在每月改善评审会议上,专职队员评审总表状态permanentteamreviewsstatusofsummarychartatmonthlykaizenreviewmeeting,蓝色标签bluetag,蓝色标签,蓝色标签,第1部分,第2部分,编号,编号,日期,日期,检查人,检查人,班次,班次,问题,问题,电气,机械,润滑,操作,仪器/控制机构,设备,其它,问题简述,电气,机械,润滑,操作,设备,仪器/控制机构,其它,问题简述,继续见背面,问题可能影响,可使用时间,性能/速度,成品质量,环境,浪费,成本,安全,其它,改正行动计划,执行人,执行人,执行人,日期,日期,日期,工作单号,根本原因/行动,更多见背面,完成日期,位置/系统/设备/零件代号,不足之处,贴上标签deficienciestagged