精益生产之全面生产维护课件

全面生产维护

(TPM)TPMTPM团队组织设备综合利用率OEETPM活动步骤RD011202全面生产维护

(TPM)TPMRD011202TotalProductiveMaintenance(TPM)TPMTPMTeamOrganizationOverallEquipmentEffectivenessTPMPhasesRD011202TotalProductiveMaintenance(精益6

过程改善流程分析控制改进定义选定题目列出客户从顾客之声中列出关建需求定出项目焦点和重要指标完成PDF测量绘制业务流程图绘制价值流程图制定数据收集计划测量系统分析收集数据过程能力分析分析提出关键因子区分关键因子验证关键因子评枯每个关键因子对结果的影响量化机会根本原因排序寻找根本原因针对关键因子改进关键因子确认发掘潜在的解决方法选择方案优化方案实行方案控制过程变革和控制制定控制计划计算最终财务过程指标项目过渡给未来项目管理者项目鉴别转化机会测量定义项目编号工具项目定义表净现值分析内部回报率分析折算现金流分析PIP管理过程RACIQuad表过程图价值分析脑力风暴投票归类法柏拉图因果图/鱼骨图FMEA查检表运行图控制图量具R&RCp&Cpk供应链加速器分析多变动图i盒状图交互作用图回归分析ANOVAC&E矩阵图FMEA脑力风暴拉系统减少设置TPM流程图标杆管理亲和图DOE假设检验力场分析图树状图甘特图查检表运行图柱状图散布图控制图柏拉图互动回顾愚巧法Revised1-12-023TotalProductiveMaintenance(TPM)精益6

过程改善流程分析控制改进定义测量分析改进控制测LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-024TotalProductiveMaintenance(TPM)LeanSixSigma

ImprovementPr课程目的学习一种方法以便:将作业流程中的起作用的所有生产要素整合为一个单一综合的衡量值（OEE）;消除导致设备故障的因素;使设备的养护清洁更易达成;用预测性保养作为一种检测工具;实施维护审查5TotalProductiveMaintenance(TPM)课程目的学习一种方法以便:5TotalProductiveLearningObjectivesLearnamethodto:IntegrateoperationalproductivityfactorsapplicableinprocessindustriesinasinglecomprehensivemeasurementEliminatefactorscontributingtoequipmentfailureImproveaccessibilityforcleaningandmaintainingequipmentUsepredictivemaintenanceasadiagnostictoolImplementmaintenanceaudits6TotalProductiveMaintenance(TPM)LearningObjectivesLearnamet个人学习意义流程作业和保养最优化一种替代传统的在故障发生时检测并修复的方法;一种源头监控和校正的先发系统;一种基于对影响过程性能的主要因素其因果系统的理解工作策略;7TotalProductiveMaintenance(TPM)个人学习意义流程作业和保养最优化7TotalProductWhat’sinItforMe?OptimizedprocessoperationsandmaintenanceAmethodtoreplacethetraditionalapproachofdetectingandcorrectingfaultyconditionsastheyoccurAproactivesystemwhichmonitorsandcorrectscausesAnoperationsstrategybasedonunderstandingthecauseandeffectsystemaffectingthemajorcontributorstoprocessperformance8TotalProductiveMaintenance(TPM)What’sinItforMe?Optimized全面生产维护(TPM)定义:一种用于监控操作,设备保养,消除计划外停机,和提高作业与保养协调程度的常识性方法。9TotalProductiveMaintenance(TPM)全面生产维护(TPM)定义:9TotalProductiTotalProductiveMaintenance(TPM)TPMDefinitionAcommonsenseapproachtomonitoroperations,maintainequipment,eliminateunscheduleddowntime,andimprovethelevelofcooperationbetweenOperationsandMaintenance.10TotalProductiveMaintenance(TPM)TotalProductiveMaintenance(TPM通过实施预防实现设备零故障和零缺陷;预防工作将立足于以下方面:维持正常的生产条件及早发现异常快速反应11TotalProductiveMaintenance(TPM)TPM通过实施预防实现设备零故障和零缺陷;11TotalPTPMAchievezeroequipmentbreakdownsandzerodefectsthroughpreventionEstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponse12TotalProductiveMaintenance(TPM)TPMAchievezeroequipmentbrea传统的反应式维护维修部门–“我们只管修理”执行所有的维修作业往往是一旦设备发生故障充当救火员的角色;负责定购和保管所有的工具,备件等物资;实施定期检修生产部门–”我们只管使用“通常不作任何维护活动一旦设备出现故障就与维修部门联系维修作业中只能停工;一直用到坏了为止13TotalProductiveMaintenance(TPM)传统的反应式维护维修部门–生产部门–TraditionalApproach

“Re-ActiveMaintenance”Maintenance–

“WEFIX”PerformallmaintenanceactivitiesPerform“FireFighting”maintenancewhenamachinebreakdownoccursOrderandadministeralltooling,supplies,etc.PerformPreventiveMaintenanceManufacturing–

“WEOPERATE”GenerallydoesnotperformanymaintenanceactivitiesContactsmaintenancewhenamachinebreakdownoccursInactiveduringmaintenanceactivities“Runit'tillitbreaks”14TotalProductiveMaintenance(TPM)TraditionalApproach

“Re-Activ主要概念 定期保养是一种基于时间长短或使用状况对设备进行检修的方法.在指定时间或在使用空档间对设备实施检修作业以防止设备发生故障.定期保养计划 预测性保养是一种基于设备状态的维护方法.根据可视信号或检测技术的情况来实施保养以防止设备发生故障.振动分析激光探测超声波检测发电机测试热感应油况分析预测性保养定期保养15TotalProductiveMaintenance(TPM)主要概念 定期保养是一种基于时间长短或使用状况对设备进行检修KeyDefinitions

PreventiveMaintenanceisatimeorusagebasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedondefinedtimeand/orusageintervalstopreventequipmentbreakdownsfromoccurring.PMSchedules

PredictiveMaintenanceisasituationbasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedonvisiblesignalsordiagnostictechniquestopreventequipmentbreakdownsfromoccurring.VibrationAnalysisLaserMeasuringUltrasoundGeneratorTestingThermographyOilAnalysisPredictiveMaintenancePreventiveMaintenance16TotalProductiveMaintenance(TPM)KeyDefinitions PreventiveMai现状分析和团队组织评估当前的操作条件:机器利用率,生产率等;维修费用(配件和人工)对实现TPM的各项工作进行优先次序评估潜在TPM倡导者及团队成员的实力挑选TPM倡导者及团队成员建立初始的实施专门小组确定团队目标17TotalProductiveMaintenance(TPM)现状分析和团队组织评估当前的操作条件:17TotalProPresentStateAnalysis

andTeamOrganizationAssessCurrentOperatingConditionsMachineutilization,productivity,etc.Maintenancerepaircosts(partsandlabor)PrioritizeorderofTPMeffortsAssesscapabilitiesofpotentialTPMChampionsandTeamMembersSelectTPMChampionandTeamMembersEstablishinitialkick-offworkshopEstablishteamgoal18TotalProductiveMaintenance(TPM)PresentStateAnalysis

andTea典型的设备评价指标利用率:设备实际运转时间与总的可利用时间的比率;=实际运行时间/可运行时间效率:实际产量与标准产量的比率=(实际产量/小时)/(标准产量/小时)产出:用一特定时间段的产量来衡量=

磅/小时,件数/小时19TotalProductiveMaintenance(TPM)典型的设备评价指标利用率:设备实际运转时间与总的可利用时间TypicalOperationalProcessMeasurementsUtilization:Theratioofequipmentactualoperatingtimetothetotalavailableoperatingtime=ActualOperatingTime/AvailableTimeEfficiency:Theratioofactualproductproducedtoastandard=(ActualParts/Hour)/(StandardPart/Hour)Output:Measureofoutputoveraspecifiedtimeperiod=lbs/hr,pieces/hr20TotalProductiveMaintenance(TPM)TypicalOperationalProcessMe设备综合利用率OEE设备综合利用率（OEE）是衡量一台设备按计划速度生产出合格产品的时间占全部时间的百分比.21TotalProductiveMaintenance(TPM)设备综合利用率OEE设备综合利用率（OEE）是衡量一台设备按OverallEquipmentEffectivenessOverallEquipmentEffectiveness(OEE)isthemeasureofthepercentoftimeapieceofequipmentisproducingqualityproductatthedesignedrate.22TotalProductiveMaintenance(TPM)OverallEquipmentEffectivenesOEE分解:六大浪费故障及轻微故障使设备中断运行的时间超过10分钟的故障或者中断时间少于10分钟的轻微故障.设置时间浪费任何与设备调整,装配,清洁相关的作业.机器空转浪费设备在运转却没有用来生产产品所耗用的时间.

速度浪费由于设备或产品的异常造成设备以低于标准速度或所设定的速度运转.品质原因浪费为确保设备产出品的品质而采取相关的作业(过程中检查).

返工浪费用于返修产品或生产出报废产品所耗用的时间.可用水平(AL)运行水平(OL)质量水平(QL)23TotalProductiveMaintenance(TPM)OEE分解:六大浪费故障及轻微故障机器空转浪费品质原因浪费可OEEBreakdown:

TheSixBigLossesBreakdownsand

MinorStoppagesMalfunctionscausingequipmenttostopprocessinggreaterthan10minutes(breakdowns)orlessthan10minutes(minorstoppages)SetupAnyactivityrelatedtoequipmentchangeover,setup,orcleaning.IdlingTimeequipmentisrunningbutnotproducingproduct.

SpeedLossesEquipmentoperatingatlessthanstandardordesignspeedduetoequipment/productabnormalityQualityFactorsActivitiesrelatedtoensuringthequalityoftheproductproducedontheequipment(in-processchecks).

ReworkLossesThetimetakentore-processproductortimetaketoproduceun-usableproduct.AvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)24TotalProductiveMaintenance(TPM)OEEBreakdown:

TheSixBigLo六大浪费的识别练习25TotalProductiveMaintenance(TPM)六大浪费的识别练习25TotalProductiveMaSixBigLossesIdentificationExercise26TotalProductiveMaintenance(TPM)SixBigLossesIdentificationOEE的计算原理承载时间(LT)设备运转总的可利用时间=40hrs可用水平(AL)运行水平(OL)质量水平(QL)OEE73%x91%x80%

26.3-3.1-2.1=80%26.3

28.9-1.5-1.1=91%28.9质量原因机器故障及轻微故障,行政事务/非作业时间机器设置与调整速度损失机器空转返工及报废

40-3.1-3.8-4.2=73%40OEE=53%ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrs27TotalProductiveMaintenance(TPM)OEE的计算原理承载时间设备运转总的可利用时间=40hCalculatingOEEElementsLoadingTime(LT)TotalHoursAvailableforEquipmentOperation=40hrsAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE73%x91%x80%

26.3-3.1-2.1=80%26.3

28.9-1.5-1.1=91%28.9QualityFactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrap

40-3.1-3.8-4.2=73%40OEE=53%ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrs28TotalProductiveMaintenance(TPM)CalculatingOEEElementsLoadin世界级的OEE性能水平承载时间(LT)同步计划运转时间及生产性防护时间可用水平(AL)运行水平(OL)质量水平(QL)OEE90%x95%x99%质量原因机器故障及轻微故障,行政事务/非作业时间机器设置与调整速度损失机器空转返工及报废OEE=85%是世界级的性能水平AL始终保持在90%以上OL维持在95%以上QL不低于99%29TotalProductiveMaintenance(TPM)世界级的OEE性能水平承载时间同步计划运转时间及生产性防护时WorldClassOEEPerformanceLoadingTime(LT)OperationTimeandPMTimeisscheduledsynchronizingthetwoAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE90%x95%x99%QualityFactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrapOEE=85%isWorldClassPerformanceTheALisconsistentlykeptatorabove90%TheOLismaintainedatorabove95%TheQLisatorabove99%30TotalProductiveMaintenance(TPM)WorldClassOEEPerformanceLoa使设备恢复到可靠状态消除故障开发PM维护保养资料库消除缺陷阶段I阶段II阶段III阶段IVTPM阶段31TotalProductiveMaintenance(TPM)使设备恢复到可靠状态消除故障开发PM维护保养资料库消除缺陷阶ReturnEquipmenttoReliableConditionEliminateBreakdownsDevelopPMInformationDatabaseEliminateDefectsPHASEIPHASEIIPHASEIIIPHASEIVTPMPhases32TotalProductiveMaintenance(TPM)ReturnEquipmentEliminateDevel六大团队活动1. 通过小规模的小组活动来提高机器的正常运行时间,消除造成停工的主要根源:机器的启动损失 机器的故障损失待料损失和生产安排不当带来的停机损失2. 使操作员熟练地参与如润滑,清洁,故障检验等基本的保养维护. 33TotalProductiveMaintenance(TPM)六大团队活动1. 通过小规模的小组活动来提高机器的正常运行时SixTeamActivities1. Usesmallgroupactivitiestoimprovemachineuptimebyeliminatingthemajorsourcesofdowntime.StartupLosses BreakdownLossesMaterialandSchedulingLosses2. Involvethemachineoperatorsaswellasskilledtradesinbasicpreventativemaintenancesuchaslubrication,cleaning,andinspectionfordefects. 34TotalProductiveMaintenance(TPM)SixTeamActivities1. Usesmal六大团队活动(续上页)3. 使用诸如振动分析类的预测工具摈弃过去那种反应式的维护模式4. 增强对设备的认知和了解以提高生产效能,减少停工时间;5. 使供应管理和生产调度协同工作以确保持续稳定的原材料供应,避免停机待料;6. 规划人员配备以确保瓶颈设备处的满员运作35TotalProductiveMaintenance(TPM)六大团队活动(续上页)3. 使用诸如振动分析类的预测工具摈弃SixTeamActivities(Cont.)3. Utilizepredictivetoolssuchasvibrationanalysistomovepastreactivetypemaintenance4. Increaseawarenessandknowledgeofequipmenttoimproveproductivityandreducedowntime5. WorkwithSupplyManagementandProductionControltoinsureaconstantflowofrawmaterialisavailabletoprecludeidling.6. Developmanningschedulesthatinsurethatbottleneckmachinesarefullystaffed36TotalProductiveMaintenance(TPM)SixTeamActivities(Cont.)3. TPM的益处提升操作员的参与感使设备恢复至更高的性能水平发现并消除早期的设备隐患减少总的制造成本减少浪费在保养设备方面树立荣誉感促进维护和生产部门之间的相互尊重与合作37TotalProductiveMaintenance(TPM)TPM的益处提升操作员的参与感37TotalProductBenefitsofTPMPromotesoperatorinvolvementRestoresequipmenttoahigherperformancelevelUncoverandeliminateprematureequipmentfailuresReducetotalmanufacturingcostsReduceswasteBuildsasenseofprideinmaintainingtheequipmentPromotescooperationandrespectbetweenmaintenanceandproduction38TotalProductiveMaintenance(TPM)BenefitsofTPMPromotesoperat职责范围精益6Sigma团队倡导者/发起人TPM团队操作员现场主管维护人员39TotalProductiveMaintenance(TPM)职责范围精益6Sigma团队39TotalProductiAreasofResponsibilityLeanSixSigmaTeamChampion/SponsorTPMTeamOperatorSupervisorMaintenance40TotalProductiveMaintenance(TPM)AreasofResponsibilityLeanSi精益6Sigma团队的任务确定一个TPM项目的需求收集有关维护成本,延迟(时延或操作延迟,设备利用率以及质量问题的历史数据与操作员进行深入沟通以了解他们的期望41TotalProductiveMaintenance(TPM)精益6Sigma团队的任务确定一个TPM项目的需求41TotLeanSixSigmaTeamRoleDeterminetheneedforaTPMProjectGatherhistoryofmaintenancecost,delay,machineavailability,andqualityproblemsInterviewOperatorstogettheirprospective42TotalProductiveMaintenance(TPM)LeanSixSigmaTeamRoleDeterm现场活动组成TPM团队负责设备维护的人员操作员一线管理人员准备必要的装备帮助TPM团队诊断异常协助跨功能培训收集整理故障标牌的拷贝并生成工作明细表提供人力资源方面的支持精益6Sigma团队的任务43TotalProductiveMaintenance(TPM)现场活动精益6Sigma团队的任务43TotalProduLeanSixSigmaTeamRoleOnflooractivitiesAssembletheTPMTeamMaintenancepersonnelOperatorsFirstlinesupervisionProvidenecessaryequipmentHelpteamdiagnoseabnormalitiesAssistskilledtradesCollectcopiesofdefecttagsandgenerateaworklistProvidepeopleresources44TotalProductiveMaintenance(TPM)LeanSixSigmaTeamRoleOnflo倡导者/发起人的角色一旦完成现场工作,接下来将:形成工作任务并跟踪其完成情况协助建立和引入正确的定期维护明细表协助维持改善结果评估设备综合利用率OEE展示TPM的改善的成就45TotalProductiveMaintenance(TPM)倡导者/发起人的角色一旦完成现场工作,接下来将:45TotaChampion/SponsorRoleUponCompletionofOnFloorEventGenerateandtrackcompletionofworkordersAssistincreationandpostingofaccuratePeriodicMaintenanceListAssistinsustainingthegainsEvaluateOverallEquipmentEffectivenessDisplayTPMimprovements46TotalProductiveMaintenance(TPM)Champion/SponsorRoleUponComp现场主管的角色指导并推广TPM概念监控现场的设备管理,保养及机器清洁工作的进行激发操作员的主人翁意识对操作员授权为TPM活动提供时间方面的准备促进生产与维护双方的合作47TotalProductiveMaintenance(TPM)现场主管的角色指导并推广TPM概念47TotalProduSupervisor’sRoleCoachandpromoteTPMConceptsMonitorongoinghousekeepingandmachinecleanlinessPromoteOperatorownershipEmpowerOperatorsProvidetimeforTPMactivitiesPromotecooperationbetweenProductionandMaintenance48TotalProductiveMaintenance(TPM)Supervisor’sRoleCoachandpro维护人员的角色

“专业的管理者”有计划的实施所有的定期保养并根据需要采取维修措施;使用振动分析,磨损度分析,热感应等预测工具;建立维护设备的保养记录与操作员协同工作并提供技术支持执行设备大修,综合调试负责执行一些特殊技能的任务,风险安全性高的作业促进TPM49TotalProductiveMaintenance(TPM)维护人员的角色

“专业的管理者”有计划的实施所有的定期保养并MaintenanceRole

“TheSpecializedCaretakers”PerformallplannedpreventativemaintenanceandtakecorrectiveactionasneededUsepredictivetoolssuchasvibrationanalysis,wearparticleanalysis,andthermographyDocumentequipmentmaintenancehistoryCooperatewithOperatorsandprovidetechnicalassistancePerformequipmentoverhaul,complexadjustmentsProvidespecialskilltasks,highsafetyrisktasksPromoteTPM50TotalProductiveMaintenance(TPM)MaintenanceRole

“TheSpeciali操作员角色

“一线管理者”清洁和缺陷检查执行基本的润滑,多点检测的工作按照核准清单的项目进行定期保养按计划执行日常清洁和整理识别刚刚发生的设备异常根据需要协助维护人员进行维修执行基本的调试工作改善提案促进TPM51TotalProductiveMaintenance(TPM)操作员角色

“一线管理者”清洁和缺陷检查51TotalPrOperator’sRole

“TheFirstLineCaretaker”CleanandinspectfordefectsPerformbasiclubrication,multi-pointinspectionPerformPeriodicMaintenanceperapprovedListPerformroutinecleaningandhousekeepingasscheduledIdentifyequipmentdefectsastheyariseAssistMaintenancewithrepairsuponrequestPerformbasicadjustmentsSuggestimprovementsPromoteTPM52TotalProductiveMaintenance(TPM)Operator’sRole

“TheFirstLin全面生产维护的七大步骤1.完成初始的机器清洁和检查2.识别机器的缺陷和泄漏并加以标示3.建立操作员及维护人员的定期检测的PM计划4. 指导操作员使用正确的保养方法5. 指导维护人员使用正确的保养方法6. 贯彻现场5S管理和组织活动7. 监控OEE并鼓励大家合作53TotalProductiveMaintenance(TPM)全面生产维护的七大步骤1.完成初始的机器清洁和检查53The7Stepsof

TotalProductiveMaintenance1. Performinitialmachinecleaningandinspection2. Identifyandtagmachinedefectsandleaks3.DevelopOperatorandMaintenancePM’s4. InstructOperatorsinproperPMtechniques5. InstructMaintenanceStaffinproperPMtechniques6. Implement5SHousekeepingandOrganization7. MonitorOEEandencouragecooperation54TotalProductiveMaintenance(TPM)The7Stepsof

TotalProductiTPM安全常识遵守/使用停工现场标牌警示程序正确的起重方法用电安全操作规范劳保装备手套工作鞋护目镜防尘口罩耳塞55TotalProductiveMaintenance(TPM)TPM安全常识遵守/使用55TotalProductivTPMSafetyHabitsFollow/UseLockoutTagoutProcedureProperLiftingTechniquesElectricalSafetyGuidelinesPersonalProtectiveEquipmentGlovesSafetyShoesGogglesRespiratorsHearingProtection56TotalProductiveMaintenance(TPM)TPMSafetyHabitsFollow/Use56TTPM步骤1初始的机器清洁和检查目的:识别需修理处并标示缺陷执行:彻底清洁机器团队所有成员参与并将所有需要维修的项目标示并记录57TotalProductiveMaintenance(TPM)TPM步骤1初始的机器清洁和检查57TotalProduTPMStep1InitialMachineInspectionPurpose:ToIdentifyneededrepairsandtagdefectsExecution:Cleanmachinethoroughly–donebyallteammembersTagandrecordallrepairsneededinaprojectnotebook58TotalProductiveMaintenance(TPM)TPMStep1InitialMachineInspTPM步骤1

“现场活动”彻底的清洁工作包括:清除所有的碎屑及其他残余物彻底地去除油污调节压缩空气更换过滤器,润滑剂等润滑移动部件及接头处清理不必要的使用工具,五金器具及备件等“你的双手肯定会脏兮兮的!”59TotalProductiveMaintenance(TPM)TPM步骤1

“现场活动”彻底的清洁工作包括:59TotaTPMStep1

“OnFloorActivities”AThoroughCleaningIncludes:RemovingallchipsandotherdebrisThoroughDegreasingCompressedairforcontrolsChangingfilters,lubricants,etc.LubricatingmovingpartsandjointsRemovingunnecessarytooling,hardware,supplies,etc.“Youhavetogetyourhandsdirty!”60TotalProductiveMaintenance(TPM)TPMStep1

“OnFloorActivitieTPM步骤1

“现场活动”维修项标示色码

标签上须标示的信息:机器的资产编号机器位置及故障位置投入使用的日期及使用人机油泄漏—橙色冷却液泄漏—绿色空气泄漏–黄色机器故障–粉红色电气问题--蓝色61TotalProductiveMaintenance(TPM)TPM步骤1

“现场活动”维修项标示色码61TotalPTPMStep1

“OnFloorActivities”RepairTagColorCodes

InformationNeededonTagsAssetnumberofmachineLocationandrelativepositionofdefectonmachineNameoforiginatoranddateOilLeaks-OrangeCoolantLeaks-GreenAirLeaks-YellowMachineDefects-PinkElectricalProblems-Blue62TotalProductiveMaintenance(TPM)TPMStep1

“OnFloorActivitie关注TPM清洁效果

降低停机时间>70%之前–砂粒及碎屑很严重无法调试运行速度降低故障接连发生之后–跨功能工作的成果更换缺损的零部件调试校正恢复至设计速度且保持品质63TotalProductiveMaintenance(TPM)关注TPM清洁效果

降低停机时间>70%之前–砂粒及碎FocusedTPMCleaningEffort

ReducedDowntimeby>70%Before–SevereGritandChipsOutofadjustmentsRunningatreducedspeedsConstantbreakdownsAfter–Cross-functionalEffortReplacedbrokenandmissingpartsCorrectedtheadjustmentReturnedtodesignedspeedwithoutincurringscrap64TotalProductiveMaintenance(TPM)FocusedTPMCleaningEffort

RTPM步骤2修复机器的缺漏目的:修复在步骤1中找到的缺漏项目注意事项:倡导者/发起人需确保标示出的问题得到修复实际的修复工作不必一定由团队成员来做;生产主管须确保机器能够使用65TotalProductiveMaintenance(TPM)TPM步骤2修复机器的缺漏65TotalProductiTPMStep2RepairmachinedefectsandleaksPurpose:TorepairitemsfoundinStep1Considerations:Champion/SponsorinsurestaggedproblemsarerepairedActualrepairsdonothavetobedonebyteammembersProductionSupervisorhastomakemachineavailable66TotalProductiveMaintenance(TPM)TPMStep2RepairmachinedefecTPM步骤2消除故障因素固定并拧紧所有的扣件,接头,螺钉及螺母替换任何缺损的部件替换任何损坏,磨损及规格不符的零部件解决所有的渗漏,溢出,喷溅,噪杂等问题提高如下环节的可操作性:清洁润滑调试检查/测试67TotalProductiveMaintenance(TPM)TPM步骤2消除故障因素67TotalProductivTPMStep2Eliminatefactorscontributingtofailure:Secureandtightenallfasteners,fittings,boltsandscrewsReplaceanymissingpartsReplaceanydamaged,wornorwrongsizepartsResolveallcausesofleaks,spillage,sprayandsplatterImproveaccessibilityinordertoaccomplish:Cleaning LubricatingAdjustingChecking/inspecting68TotalProductiveMaintenance(TPM)TPMStep2EliminatefactorscoTPM步骤3建立操作员和维护人员合作的PM计划确保发出完善的定期检测的查检表目的:注意事项:由TPM项目小组建立PM计划谁来执行任务任务执行的频率(例如每天,每周等)69TotalProductiveMaintenance(TPM)TPM步骤3建立操作员和维护人员合作的PM计划69TotaTPMStep3DevelopOperatorPM’sandMaintenancePM’sPurpose:ToinsureadequatepreventativemaintenancechecklistsarepostedConsiderations:TPMProjectTeamtodevelopPM’sWhoistoperformtasksFrequencyoftasks(i.e.,daily,weekly,etc.)70TotalProductiveMaintenance(TPM)TPMStep3DevelopOperatorPM’TPM步骤4由操作员执行的PM作业目的:尽早发现问题,准备周期保养,遵循5S规程注意事项:操作员负责按照管理文件执行PM工作;生产主管须确保PM工作的有效实施71TotalProductiveMaintenance(TPM)TPM步骤4由操作员执行的PM作业71TotalProdTPMStep4PMactivityperformedbytheOperatorPurpose:Todetectearlyproblems,providetheserviceinterval,andinsure5SprocedureisfollowedConsiderations:OperatorisresponsibletoperformPM’sasdocumentedProductionSupervisortoinsurePM’sareeffective72TotalProductiveMaintenance(TPM)TPMStep4PMactivityperformeTPMTPM使操作员更加独立地自我管理和控制;操作员时时关注小问题的发生就有可能: 迅速地发现潜在的问题修正现有问题确定状态正常良好地维持设备整体状况73TotalProductiveMaintenance(TPM)TPMTPM使操作员更加独立地自我管理和控制;73TotalTPMTPMmakestheoperatormoreindependentTheoperatorseesthesmallproblemsnowwiththepossibilityof: QuicklynotingpotentialproblemsCorrectingthecurrentsituationRecognizingnormalconditionsMaintainingthemachineingoodoverallcondition74TotalProductiveMaintenance(TPM)TPMTPMmakestheoperatormore自主维护管理指的是操作员参与自己所操作的设备的维护作业怎样使操作员更加自主,实现自我管理:利用文件管理明确维护/生产作业的规定明确操作员如何进行日常检测进行基本的操作,维护及故障检测的培训使日常作业直观,一目了然明确识别须监督管理的项目75TotalProductiveMaintenance(TPM)自主维护管理指的是操作员参与自己所操作的设备的维护作业75TAutonomousMaintenanceReferstoactivitiesinvolvingoperatorsinthemaintenanceoftheirownequipmentHowtomaketheoperatormoreindependent:MakedocumentationavailableDefinemaintenance/manufacturingactivitiesShowoperatorhowtoperformdailychecksTraininbasicoperation,maintenance,anddefectdetectionMakedailyactivitiesvisibleClearlyidentifyitemstosupervise76TotalProductiveMaintenance(TPM)AutonomousMaintenanceReferst落实自主维护管理确定过程实施中的关键机器及设备执行初步清洁工作清除脏污及污染源建立清洁和润滑标准就设备的保养需求对操作员进行培训贯彻实施一个综合性的维护系统对保养效果进行定期审查77TotalProductiveMaintenance(TPM)落实自主维护管理确定过程实施中的关键机器及设备77TotalAutonomousMaintenanceImplementationIdentifyprocesscriticalmachineryandequipmentPerforminitialcleaningResolvesourcesofdirtandcontaminationCreatecleaningandlubricationstandardsTrainoperatorsonequipmentmaintenancerequirementsImplementacomprehensivemaintenancesystemEstablishperiodicauditsofmaintenanceeffectiveness78TotalProductiveMaintenance(TPM)AutonomousMaintenanceImpleme为什么清洁?不恰当的清洁所带来的负面影响:故障产品缺陷加快设备磨损产量降低设备磨损正常磨损:尽管正确操作仍然会发生加快磨损:由于误操作及疏忽于保养导致加快磨损79TotalProductiveMaintenance(TPM)为什么清洁?不恰当的清洁所带来的负面影响:79TotalPWhyClean?AdverseeffectsofinadequatecleaningFailureProductdefectsAccelerateddeteriorationThroughputlossEquipmentdeteriorationNormaldeterioration:occursdespitecorrectuseAccelerateddeterioration:quickerdeteriorationoccurringduetomisuseinoperationandneglectofmaintenance80TotalProductiveMaintenance(TPM)WhyClean?Adverseeffectsofi清洁可作为磨损检查清洁可减缓磨损速度接触设备可发现异常情况采取保养措施可延长使用寿命,避除故障81TotalProductiveMaintenance(TPM)清洁可作为磨损检查清洁可减缓磨损速度81TotalProdCleaningasDetectionofDeteriorationCleaningreducesaccelerateddeteriorationPhysicalcontactwithequipmentexposesabnormaloperationconditionsPreventiveactiontakenextendsusefullifeandavoidsbreakdowns82TotalProductiveMaintenance(TPM)CleaningasDetectionofDeter常见的设备缺陷断线软管磨破漏油漏气散热剂泄漏托架损坏电线裸露多余及废弃的器具防护装置损坏或不见83TotalProductiveMaintenance(TPM)常见的设备缺陷断线83TotalProductiveMTypicalDefectsFoundBrokenflexWornhosesOilleaksAirLeaksCoolantleaksBrokenBracketsFrayedwiresUnnecessaryandobsoletetoolingDamagedormissingguards84TotalProductiveMaintenance(TPM)TypicalDefectsFoundBrokenfl设备故障专家估计与移动装置相关的机器故障有60%是由于缺乏或不适当的润滑导致的;建立设备故障资料库收集并管理故障资料分析故障趋势及形式定期展开和发布总结报告包括用于定期回顾之用的会议议程报告85TotalProductiveMaintenance(TPM)设备故障专家估计与移动装置相关的机器故障有60%是由于缺乏或EquipmentFailuresExpertsestimatethat60%ofmachinebreakdownsassociatedwithmovingpartsareduetolackoforimproperlubricationpractices.EstablishanequipmentfailuredatabaseGatherandmanagefailureinformationAnalyzefortrendsandpatternsDevelopandissueperiodicsummaryreportsIncludereportsasameetingagendaforregularreview86TotalProductiveMaintenance(TPM)EquipmentFailuresExpertsestiTPM步骤4(续）目视管理张贴设备润滑工作示意图标示油位玻璃管的上下线所有的气管,水管,油管及冷却剂管区分标示张贴OEE的图表分析公布本年度截至目前为止的保养成本公布5S审查的得分情况87TotalProductiveMaintenance(TPM)TPM步骤4(续）目视管理87TotalProductTPMStep4（Con.)VisualsControlsLubricationplacardsinplaceUpperandlowersightglassesinplaceAllair,water,gas,andcoolantlinesarelabeledOEEpostedYTDMaintenancecostsposted5SAuditScoresposted88TotalProductiveMaintenance(TPM)TPMStep4（Con.)VisualsContTPM步骤5由维护人员执行的PM作业目的:预防机器故障在发生故障之前解决注意事项:PM作