TPM方法(英文)

1、TPM METHODTPMGLOBAL INDICATOR: THE TRSTRS =Quality production time Opening timeTRS =Number of good parts produced x Cycle time Opening time Cycle time = Initial reference + improvementsInitial ref. = Minimum technical time TPMRELIABILITY INDICATORAverage of good working time MTBF = Actual production

2、 time Number of real stoppages TPMRELIABILITY INDICATOR = MTBF (mean time between failure) It is the average duration in minutes during which the machine or the installation functioned without any stoppages.The stoppages are:- machine breakdowns - breakdowns related to tools - breakdowns related to

3、the product - stoppages for change-overs (used or broken)- stoppages for frequent adjustments - stoppages for inspection (SPC sampling)- stoppages for maintenance Stoppages for tool change-overs are not taken into account TPMBREAKDOWNS AND MICRO-STOPPAGES: nBREAKDOWNSStoppages = 5minsNot often Syste

4、matically notedStoppage affects the entire working groupIntervention of an expertResearch necessary before start-upIdentifiable causesnMICRO-STOPPAGESStoppages 15 mins: Expert 30 mins: Maintenance2134TPM: BREAKDOWNSTREATMENT METHODOLOGYCreate or modify if necessary the routine sheet of preventive ma

5、intenance Apply the new standard Steering: SupervisorExecution: Maintenance Prof. + SupervisorMethod: Update and validation of routine sheet. Steering: SupervisorExecution : Operators + Maintenance Prof.Method: Following the level of maintenance, define the training needs and train the contributorsS

6、teering: Animation to reach objectives Execution: Application of formalised instructions56The history of breakdowns is the back-up document of the process, it is found on the machine and is available for everybody.It is completed by the person carrying out the given taskTPM: BREAKDOWNSWEEKLY MEETING

7、SUBJECT: breakdowns encountered during the weekPARTICIPANTS: supervisor and maintenance technician GOAL: ensure that the definitive measures have been implemented to avoid any recurrence of breakdownsPLAN:weekly breakdown inventory for the past weekexamine causesactions to be implemented TPMMICRO-ST

8、OPPAGES : CHARACTERISATIONShut-down 5mnOftenNo recordsLittle or no perception by the groupEasy start-up without elimination of the cause (suppression of the effect)Unidentified cause Little motivation to eliminate them because little perceived impact on production Strongly involves the operators and

9、 automatic installation people for tasks without Added Value TPM: MICROSTOPPAGESTREATMENT METHODOLOGYFrom the noted effect, define the diagnosis method of causesRegister the micro-stoppagesSelect the micro- stoppage to be treatedQuantify the causes (counting)Identify the possible causes of the micro

10、- stoppage PROCESSPeople Concerned MethodsSteering: SupervisorExecution: Operators, Supervisor, Maintenance and Manufacturing Engineering TechniciansMethod: meetings on the shopfloor with problem solving tools ( Pareto - Brain Storming - 5M cause-effect diagram - 5 Whys)Steering: SupervisorExecution

11、: Technicians and Operators Method: Use of exhaustive film of all the machine anomalies (with follow-up of human intervention). ParetoSteering: SupervisorExecution: OperatorsMethod: Noted on numbered workstation form (counting)Steering : SupervisorExecution: Maintenance ExpertMethod: Formalise and t

12、rain the operator in diagnosis 21354Select the machinesTPM: MICROSTOPPAGESTREATMENT METHODOLOGYCreate or modify if necessary the routine sheet of preventive maintenance Select the causes to be treated in prioritySet-up the solutionsLook for solutionsContinue with the counting of causes of the micro-

13、stoppageSteering: SupervisorExecution: Manufacturing Engineering Technician - Maintenance Prof. - Operators Method: Depending on the level of machine modification and/or level of maintenanceDefine the training needs and train the contributorsSteering: SupervisorExecution: PSG members Method: Pareto

14、- Balancing - Brain stormingSteering: SupervisorExecution: OperatorsMethod: Noted on workstation form (counting)Apply the new standard97610811TPMROLE OF THE OPERATORnPREVENTIVE MAINTENANCECarry out production operations correctly and set up the machineDo inspection of the machine everydayMaintain th

15、e performance of the machineCleaning, Greasing,TighteningApply the self maintenance routine sheetsCommunicate with maintenance departmentCarry out the counting of micro-stoppage registration sheetsCarry out the recording of micro-stoppages causesParticipate with engineering and trial of new equipmen

16、tTPMROLE OF THE OPERATORnCURATIVE MAINTENANCE Prepare the machine conditions for repair Give their feelings about the machine and their opinions about the working conditionsAssist technicians during repair and heavy maintenanceParticipate in PSG to identify solutions for micro-stoppage and breakdown

17、TPM: MICRO-STOPPAGESOPERATOR TRAININGnSteps during which the operator becomes trainedElaboration of cause-effect diagram Diagnosis of the causes of micro-stoppages Research for solutionsCreation or modification of the preventive maintenance routine sheetnAcquired knowledge Construction of a cause-ef

18、fect diagram, methodology and research of causes, knowledge of factors responsible for the correct functioning of the machine Diagnosis methodology of a malfunctionTechnical knowledge Knowledge of machine maintenance needs TPMnPREVENTIVE MAINTENANCETrain and assist the operatorsImprove the reliabili

19、ty of the machine and standardise identical equipmentcapability, featurescycle timeImprove maintainabilityDo technical inspection that need expertiseContinuous improvement of maintenance organization Participate in the engineering of new equipmentROLE OF THE MAINTENANCE DEPARTMENTTPM nExamples of vi

20、sual meansPosition markings (machines, tooling, tools, products, etc.) Colour coding by function, product or workshop Light paint on dirty objects Cupboards without doors Etc.VISUAL ORGANISATION Experience analysis TPM: preventive maintenance JanvierFvrierMarsAvrilMaiJuinJuilletSeptembre Octobre Nov

21、embre DcembreVidange moteur Vrification serrage vis support bti Graissage carter Contrle tension et usure courroie Contrle dimensionnel axe MachineAtelierConfiguration initialeDate:EnsembleNote:Nouvelle configurationBoard for scheduling the preventive maintenance Preventive maintenance procedureRepo

22、rt of the inspection anomaliesHistorical account123345Weekly meetings Property of Valeo - Duplication prohibited JanvierFvrierMarsAvrilMaiJuinJuilletSeptembreOctobreNovembreDcembreVidange moteur Vrification serrage vis support bti Graissage carter Contrle tension et usure courroie Contrle dimensionn

23、el axe Board or datasheet for scheduling the preventive maintenance To be doneJLObserved defectfinishedJLNothing wrongTPM: preventive maintenanceWorking conditionsProperty of Valeo - Duplication prohibitedEXAMPLESObvious TPMnVisual mark for Min and Max levelsnMark to locate the stop position of a mo

24、bile part of a machinenRed mark for pressure manometer nImportant screws with nut tightening are repaired with visual mark (see 2 on page 49)nGrease locations are highlighted with arrows, numbered and colourednPart list is labelled on containers (oil tank, pump for greasing operations.) EXAMPLESObvi

25、ous TPM 123FIELD APPLICATIONTPM PILOT WORKSHOP nCRITERIALine or bottle-neck machines (in order to gain capacity and availability)Presenting a low MTBFStrongly penalising the flowSemi-automatic installations consisting of manual workstations (the activity of the operator depends upon the good functio

26、ning of the installation)schedules nPreliminary 5S operationsimplementation of cleaning procedureimplementation of inspection procedurevisual organisationnTPM methodologyTRS measure MTBF measureTreatment of breakdowns Treatment of micro-stoppages n Complement the preventive maintenance procedure TPM

27、TPM: MICROSTOPPAGESTREATMENT METHODOLOGYFrom the noted effect, define the diagnosis method of causes Record the micro-stoppagesSelect the micro- stoppage to be treatedQuantify the causes (counting)Identify the possible causes of the micro- stoppage PROCESSPeople Concerned MethodsSteering: Supervisor

28、Execution: Operators, Supervisor, Maintenance and Manufacturing Engineering TechniciansMethods: meetings on the shopfloor with problem solving tools ( Pareto - Brain Storming - 5M cause-effect diagram - 5 Whys)Steering: SupervisorExecution: Technicians and Operators Methods: Use of exhaustive film o

29、f all the machine anomalies (with follow-up of human intervention). ParetoSteering: SupervisorExecution: OperatorsMethods: Noted on numbered workstation form (counting)Steering : SupervisorExecution: Maintenance ExpertMethods: Formalise and train the operator in diagnosis 21354Select the machinesTPM

30、: MICROSTOPPAGESTREATMENT METHODOLOGYCreate or modify if necessary the preventive maintenance routine sheetSelect the causes to treat in priority Set-up the solutionsLook for solutionsContinue the counting of the causes of the micro-stoppageSteering: Maintenance, Manufacturing EngineeringExecution:

31、Manufacturing Engineering Technician - Maintenance Prof. - Operators Method: Depending on level of machine modification and/or level of maintenanceDefine the training needs and train the contributors Steering: PSG LeaderExecution: PSG team membersMethod: Pareto - Balancing - Brain stormingSteering:

32、SupervisorExecution: OperatorsMethod: Registered on workstation sheet (counting)Apply the new standard97610811Look for solutionsTPM WORKSHOPS RESULTSFEEDBACK TO DESIGNspecification bookset up / start of the machineUpdating of preventive routine datasheetCollection of experienceBuilding of preventive

33、 maintenance bookletFMECA5STPMSupplieradvicesbreakdownMicro-stoppagesQualitySafetyPREVENTIVE MAINTENANCE ELABORATION FMECATPM: FMECAnFailure Modes and Effects Criticality AnalysisTool to improve understanding of the working conditions and the stop risks of a machineIdentify the weak parts of a machi

34、neStudy effects of failure (Reliability Maintainability Risk Safety)Study and plan solutions for corrective and preventive actions to improve reliabilityRules to operate the machine to its optimum TPM: FMECAThinking approachCAUSE : Why did it occur ?EFFECT : What has happened according to the machin

35、e operator ? The machine itself ?TPM: FMECAQuotationGravity valueMinor Midle Critical disastrous Repair time 60mn or quality / saafety risk Frequency valueAnnual quarterly weekly daily Less 1 fault/yearrMax 1 fault/quaterMax1 fault/week1 fault/dayDetectionprobability Minor Middle Critical disastrous

36、 Detectionprobability Previous signs before failure leading to preventive maintenancePrevious indications but none noticeable for the operatorNo Previous sign before failurePrevious signs before failure but difficult to see by the operatorCorrectives actionsTPM: FMECAnRisk priority indexIPR = G x F x D11664IPR causes number correctives actions necessaryTHE MAINTENANCE PLANTPM nThe current maintenance plans are established from recommendations