9 ANPS 全员生产保全 (简体字)

1、Total Productive Maintenance全 员 生 产 保 全. Total Productive Maintenance 全员消费保全 Meaning of TPM 全员消费保全之意义 A Japanese Kaizen Strategy focus on improving the efficiency of machine to gain the overall profit of the company. 为日本的改善战略活动之一种，着眼于改良 机器设备的效率，以提升公司整体的利益。. Total Productive Maintenance 全员消费保全 Featur

2、es of TPM TPM 之特徵 Emphasize overall company efficiency 着重企业整体的效率化 Achieve Zero Defect, Zero Accident, Zero Shutdown 追求零不良、零灾祸、零缺点 Involve all departments,Production, R&D, Marketing 包含一切部门，消费、开发、营业部门 All employees participation, from CEO to operator 从总经理到作业员均参与 Kaizen by Small Group Activities 以小团队活动

3、来进展改善. Total Productive Maintenance 全员消费保全 Benefits of implementing TPM TPM 之目的 Reduce shutdown time to deliver product on time 减少停机，交期准时 Stabilize Machine Capability to assure quality level 稳定性能，确保质量 Increase Overall Equipment Efficiency to reduce cost 提升效率，降低本钱 Upgrade operation skills to guarante

4、e safety 提升技艺，保证平安 . Total Productive Maintenance 全员消费保全 Level of Maintenance 保全的境界 BM : Breakdown Maintenance 事后保全 PM : Preventive Maintenance 预防保全 CM : Corrective Maintenance 改良保全 MP : Maintenance Prevention 保全预防. Total Productive Maintenance 全员消费保全 6 Pillars of TPM TPM六大支柱 Users Maintenance 自主保全

5、Planned Maintenance 方案保全 Case Correction 个别改善 Initial Management 初期管理 Easier Manufacturing 易制设计 Education Training 教育训练. Total Productive Maintenance全员消费保全 Relationship between Pillars and Levels 支柱与境界之关连 Breakdown 事后Maintenance 保全Users Maintenance 自主保全Planned Maintenance 方案保全Case Correction 个别改善Edu

6、cation Training 教育训练Initial Management 初期管理Easier Manufacturing 易制设计Preventive 预防Maintenance 保全Corrective 改良Maintenance 保全Maintenance 保全Prevention 预防. Total Productive Maintenance 全员消费保全 6 Major Losses of Machine 设备六大损失 Equipment Breakdown 缺点损失 Minor Stoppage 瞬停损失 Changeover/Adjustment 换模损失 Defects/

7、Rework 不良损失 Speed Reduction 退化损失 Waiting Operation 等待损失. Total Productive Maintenance全员消费保全 Relationship among Losses, Pillars and Job Function (1/2) 损失、支柱与职务之关连(1/2) Losses 损失 Pillars 支柱 Equipment Breakdown 缺点损失Users Maintenance 自主保全Planned Maintenance 方案保全Case Correction 个别改善Education Training 教育训

8、练Initial Management 初期管理Easier Manufacturing 易制设计Minor Stoppage 瞬停损失Changeover Adjustment 换模损失Defect Rework 不良损失Speed Reduction 退化损失Waiting Operation 等待损失. Total Productive Maintenance全员消费保全 Relationship among Losses, Pillars and Job Function (2/2) 损失、支柱与职务之关连(2/2) Pillars 支柱 Job 职务 Users Maintenanc

9、e 自主保全Operator 作业员Supervisor 线 长Maintenance Technician 保全员Consultant 顾 问Maintenance Engineer工程师Develop Engineer 开 发Planned Maintenance 方案保全Case Correction 个别改善Easier Manufacturing 易制设计Initial Management 初期管理Education Training 教育训练. Total Productive Maintenance 全员消费保全 Measures for Equipment 设备绩效衡量目的

10、Overall Equipment Efficiency 设备总合效率(可动率) Measure of the available, performance and quality efficiency of equipment 衡量设备的时间、性能及质量之效率 Mean Time Between Failures 平均缺点间隔时间 Mean Frequency Of Failure 平均缺点次数 Measure of the reliability of equipment 衡量设备的可靠才干 Mean Time To Repair 平均修护时间 Measure of the maintai

11、nability of equipment 衡量设备的维修才干. Total Productive Maintenance 全员消费保全 Definition of OEE(1/2) 设备总合效率之定义OEE可动率= Equipment Available Efficiency 设备时间效率 x Performance Efficiency 性能效率 x Quality Efficiency 质量效率Equipment Available Efficiency 设备时间效率: Loss of breakdown 缺点损失 Loss of changeover 换模损失 Loss of insp

12、ection 检查损失 Loss of waiting 等待损失 . Total Productive Maintenance 全员消费保全 Definition of OEE(2/2) 设备总合效率之定义 Performance Efficiency 性能效率: Loss of minor stoppage 瞬停损失 Loss of dummy running 空转损失 Loss of speed reducing 退化损失 Quality Efficiency 质量效率: Loss of defects 不良损失 Loss of rework 重修损失 Loss of retest 重测损

13、失 . Total Productive Maintenance 全员消费保全 Calculation of OEE 可动率的算法(1/2)(A) Total Time a day 每日时间= 60min分 x 24Hrs小时 = 1440min分(B) Planned Shutdown Time 方案停机时间= 480min分 b1) Break Time 休憩时间= 60min 分 x 2 = 120min分 b2) Preventive Maintenance 预防保全时间 = 60min 分 x 2 = 120min分 b3) No Order Waiting Time 无定单等待时间

14、 = 60min 分 x 4 = 240min分(C) Production Scheduled Time 消费方案时间(=A-B) = 960min分(D) Unscheduled Down Time 不测停顿时间= 100min分 d1) Breakdown 缺点 = 20min分 d2) Changeover/Set up/Adjustment换模/安装/调整=40min分 d3) Tools Change/Inspection 刀具改换/检查= 30min分 d4) Waiting Operator/Materials 等待人员/资料= 10min分 . Total Productiv

15、e Maintenance 全员消费保全 Calculation of OEE 可动率的算法(2/2)(E) Available Operation Time 有效消费时间(=C-D) = 860 min分 Equipment Available Efficiency 设备时间效率 ( = E/C = 860/960 ) = 89.6%(G) Total Output Quantity 全部消费数量( = 1450 pcs个)Ideal Cycle Time 实际周期时间( = 0.5 min分/pc个 ) Equipment Performance /Efficiency 设备性能效率 =

16、(G x H)/E = 84.3 %Total Rejected Quantity 总不良数= 200 pcs 个 Equipment Quality Efficiency 設備品質效率 = (G -J)/G = 86.2 % OEE 可动率= F x I x K = 89.6% x 84.3% x 86.2% = 65.1% or 或者 = (G-J) x H/C = 65.1%. Total Productive Maintenance 全员消费保全 What is Users Maintenance 何谓自主保全 The user of equipment is responsible

17、for some basic maintenance activities of equipment 由运用机器设备的操作者，担任从事 一些机器设备的根本保全任务之意。. Total Productive Maintenance 全员消费保全 Objectives of Users Maintenance自主保全之目的 Increase the users care on equipment. 提升操作者对设备的关怀度 Increase the users capability to operate equipment 提升操作者对设备的操作才干 Increase the users capa

18、bility to find out the abnormal situation of equipment earlier. 提升操作者能早期觉察设备异常情况之才干 To increase the reliability and OEE of equipment. 提升设备的可靠才干及提升设备的可动率. Total Productive Maintenance 全员消费保全 Seven Steps of Users Maintenance 自主保全展开七步骤1) Initial cleaning and check 初期清扫点检2) Elimination of sources of con

19、tamination 排除困难发生源头3) Establish standards of cleaning and lubrication 作成清扫及光滑基准4) Implement general inspection and training 实施总点检及技艺教育5) Implement inspection by user 实施自主点检6) Implement quality assurance 实施质量保证7) Maintain standards and continue improvement 自主维持管理及提升程度.Purpose 目的Learn the teamwork act

20、ivities and leadership skills 学习团队活动及指点技艺Learn the concept of “cleaning means check 学习 “ 清扫即是点检 之观念Learn the safety operation procedure 学习平安操作程序Expose the abnormal condition of equipment and correction 找出设备异常之处及复原 Total Productive Maintenance 全员消费保全 Step 1 of Users Maintenance (1/2) 自主保全第一步骤(1/2)Ini

21、tial cleaning and check 初期清扫点检.Main Activities 主要活動 Remove unneeded parts 设备不要之物移走Clean equipment 清扫设备Discover abnormal condition 觉察异常之处 * List of difficult cleaning 清扫困难表 * List of unstable condition 不佳形状表 * List of query 疑惑一览表 * List of contamination source 污染源头表Correct the abnormal condition 复元异常

22、之处 * Red Tag for abnormal condition异常之处贴上膏药单(红单) Total Productive Maintenance 全员消费保全 Step 1 of Users Maintenance (2/2) 自主保全第一步骤 (2/2)Initial cleaning and check 初期清扫点检.Purpose 目的Learn the basic skills of maintenance 学习根本保全技艺Learn the corrective skills for abnormal condition 学习 矫正异常 之技巧Increase reliab

23、ility of equipment by reducing contamination 减少设备污染，以提升可靠性Keep equipment always in clean condition to increase maintainability 坚持设备清洁形状，以提升保全性Improve equipment to be easier for clean and check 改善设备使容易清扫及点检 Total Productive Maintenance 全员消费保全 Step 2 of Users Maintenance (1/2) 自主保全第二步骤(1/2)Elimination

24、 of Difficulties 排除困难发生源头.Main Activities 主要活动Eliminate difficult cleaning area 排除清扫困难处所Prevent contamination 防止污染飞散对策Improve the efficiency of clean and check 提升清扫及点检效率 Total Productive Maintenance 全员消费保全 Step 2 of Users Maintenance (2/2) 自主保全第二步骤(2/2)Elimination of Difficulties 排除困难发生源头. Total Pro

25、ductive Maintenance 全员消费保全 One Point - Lesson 每日一课 Purpose 目的 Use as a training tools for operators, technicians and engineer 做为作业员、维修员、工程师的训练教材 Share and transfer the Kaizen Skills of equipment 分享及传承对设备的改善技巧 Key Points for Writing 写作要点 Short in single page 简短一页完成 Better use drawings, picture or dia

26、grams 最好运用 绘图、照片方式 10 minutes or less for presentation 能在10分钟内讲解完成 .Purpose 目的Learn to establish maintenance standards 学习本人制定保全规范Realize the importance of adhering to standards 了解遵守规范之重要性Maintain basic condition of equipment to prevent deterioration 维持设备根本条件，防止劣化Apply visual management skills 实施目视管理

27、 Total Productive Maintenance 全员消费保全 Step 3 of Users Maintenance (1/2) 自主保全第三步骤(1/2) Establish Standards of Cleaning and Lubrication 做 成 清 扫 及 润 滑 基 准.Main Activities 主要活动Develop standards of cleaning and lubrication 开展清扫及光滑基准Shorten the time of cleaning and lubrication 缩短清扫及光滑时间Visual management fo

28、r easier lubrication 容易光滑之目视化Train the skills of cleaning and lubrication 训练清扫及光滑之技巧 Total Productive Maintenance 全员消费保全 Step 3 of Users Maintenance (2/2) 自主保全第三步骤(2/2) Establish Standards of Cleaning and Lubrication 做 成 清 扫 及 润 滑 基 准.Purpose 目的Learn the knowledge and skill of checking equipment 学习有

29、关设备点检的知识及技巧Learn the skills of restoration and improvement 学习设备复原及改善技巧More application of visual management skills 目视管理技巧的深层运用Maintain and improve routine check activities to increase reliability of equipment 做好及改良日常点检活动，以提升设备可靠性 Total Productive Maintenance 全员消费保全 Step 4 of Users Maintenance (1/2)

30、自主保全第四步骤(1/2) Implement general inspection and training 实 施 总 点 检 及 技 能 教 育.Main Activities 主要活动Train the inspection skill for each check item. 对每一点检工程实施点检技艺教育训练Implement inspection for all check items. 对一切点检工程，进展点检活动Continue to discover problem areas and to Kaizen. 继续觉察问题及改善Make sure to finish all

31、check items within limited time. 确保能在一定时间内完成点检工程 Total Productive Maintenance 全员消费保全 Step 4 of Users Maintenance (2/2) 自主保全第四步骤(2/2) Implement general inspection and training 实 施 总 点 检 及 技 能 教 育.Purpose 目的 Train to use “five senses to discover potential problem area. 训练以“五感 来觉察问题症兆To deploy the Kaiz

32、en experience to other equipment. 将设备改善阅历推行到其它的设备Discover potential problem areas for earlier correction by daily cleaning and inspection activities. 透 过每日清扫及点检活动，提早觉察潜在问题并矫正 Total Productive Maintenance 全员消费保全 Step 5 of Users Maintenance (1/2) 自主保全第五步骤(1/2)Implement inspection by user 实施自主点检.Main A

33、ctivities 主要活动Establish daily check list of cleaning and inspection based on standards. 根据清扫及点检规范，作成每日查核表Strictly adhere to implement daily cleaning and inspection. 严厉地遵行每日自主清扫及点检Strive to achieve the goal of zero rate of breakdown. 努力追求零缺点为目的Take corrective action immediately if necessary 必要时能立刻采取改

34、善措施 Total Productive Maintenance 全员消费保全 Step 5 of Users Maintenance (2/2) 自主保全第五步骤(2/2)Implement inspection by user 实施自主点检.Purpose 目的 Learn the effects of equipment condition to the process capacity and quality level. 学习设备的情况对制程才干及质量程度的影响Learn the importance of adhering to Standard Operation Procedu

35、re and its effect to quality level. 学习遵守作业规范书对质量影响的重要性Review quality assurance capability of equipment. 检讨设备的质量保证才干Try to improve the process capability of equipment. 设法提升设备的工程才干 Total Productive Maintenance 全员消费保全 Step 6 of Users Maintenance (1/2) 自主保全第六步骤(1/2) Implement quality assurance 实施质量保证.Main Activities 主要活动Enhance the awareness of “ 3 NO Principles of quality assurance 强化质量三不原那么的认知 * No accept defects 不接受不良品 * No produce defects