设备自主维护

AutonomousMaintenance自主维修

Guidelines指导方针NHAGNHCETherearetwotypesofautonomousactivities:oneisfocusedontheareaswithintensivemachineryandtheotherontheareaswithahighleveloflaborcontent.有两种自主维修活动，一是重点放在加强机器区域，另一个是劳力较多的区域。TheactivityregardingthemachineryiscalledAutonomous

MaintenanceandtheactivityregardingtheorganizationoftheworkareaiscalledWorkplaceOrganization关于机器方面的活动叫自主维修，关于工作区域组织的活动叫工作场所组织。AutonomousMaintenance自主维修Theautonomousmaintenanceispartofthoseactivitiesthathasasthemainscopetopreventbreakdownsandmicrofailuresduetolackofbasicconditionsofthemachines.自主维修是那些活动的一部分，这些活动能够预防由于机器基本条件缺乏造成的损坏和小故障。Theautonomousmaintenanceisnotatechnicalactivity,liketheprofessionalmaintenance,butitmustbelearnedandappliedbyallthepeoplethatinteracteverydaywiththemachines.It’sbasedonthecompetenciesoftheoperatorsandusingthefivesensesandverysimpletoolslikepaintbrushestoeliminatethedirt,plastictoprotectthemachineryetc.自主维修不是一种技术活动，像专业维修，但是每天使用机器的人都要学会应用此自主维修技术。它是在操作工能力基础上的，用五官，使用很简单的工具，如用油漆刷来清除污渍，用塑料保护机器等。WhatisAM?(1/2)什么是自主维修？ThetypicaloperationsofAMarecleaning,lubrication,adjustmentoffasteners,parameterscontrol,temperaturecontrol,noiseandvibrationcontrol,minorrepairsandminorimprovements.自主维修典型的操作是清洁，上油，调节阀，参数控制，温度控制，噪音和振动控制，小修复和小改善。TheAMisasystematicapproachtowardsthemachineryimprovementwiththeobjectivetoautonomouslymanage,bytheproductionoperators,theinspections,thecontrolandrestorationofthebasicconditionsofthemachineryeliminatingthesourcesofdirt,throughastrictapplicationandacontinuousimprovementofthestandards.自主维修是进行机器改善的系统方法，拥有自主管理的目标，由生产操作工清除污渍来源，通过严格遵守运用不断改善的标准，进行检查，控制和恢复机器的基本条件。RegardingAMandPM,uptostep3,it’sveryimportanttoalwayskeepseparatedthepreventiveactivitiesamongstthetwopillars.关于自主维修和专业维修，一直到步骤3，要一直将两支柱中的预防性维修分开很重要。WhatisAM?(2/2)什么是自主维修？Themachinescanbreakbecauseofdeterioration,increasingofthestressthattheyshouldsupport,causedbythelossofbasicconditions.Likewisetheycanbreakduetohumanerrorsortodesignerrors.

机器可能损坏，是因为磨损，所能承受的压力增加，基本条件缺乏造成的。同样，也可以是人为失误或设计错误造成的。Whydothemachinesbreak?(1/2)机器为什么会损坏呢？BREAKDOWN损坏DETERIORATION磨损EXCESSIVESOLICITATIONS额外的引发SCARCEROBUSTNESS不够耐用1Lackofmaintainingthebasicconditions维修基本条件缺乏23465Lackofobservancyoftheoperatingconditions不遵守操作条件Norestorationoftheanomalies没有对异物进行恢复Designweakness设计不足Badcompetenciesofoperatorsandmaintenancepeople操作工和维修人员的能力差Externalinfluences:material,spareparts,environmentecc.外部影响：材料，备用零件，环境等。Whydothemachinesbreak?(2/2)机器为什么会损坏？Thedeterioration

happensastimegoesoncausedbyabadmaintenancenotableto“maintain”thebasicconditionsorbythebadcompetenciesoftheoperatorswhomdonotperformcorrectlytheinspections.由于维护不当，不能维护基本条件或能力差的操作工不能正确的完成检查，时间久了就会发生磨损。Theincreaseofstressandtheexcessivesolicitationsareduetooperatingerrors(badcompetenciesoftheoperators),badinterventionsorduetothefactthattheoperatingconditionsarenotstrictlyobservedbytheoperatorsandofthenonobservanceofthebasicconditions.由于操作失误（操作工能力差），不良干涉或操作工不能严格遵守操作条件及不遵守基本条件，导致压力增加，额外的引发出现。Thescarcerobustnessofthemachineryistheresultsoferrorsorweaknessofthedesignsofthemachinesorsinglecomponents,ofconstructionorinstallationerrors.Toavoidthedeteriorationofthemachinery,itisnecessarytoassurethemaintenanceofthebasicconditions.Thisispossiblethroughthepreventivemaintenance,activitiescarriedoutbytheAMandPMpillars.机器不耐用是因为机器零件的设计、构造错误或不足，或安装错误。为了避免机器磨损，保证机器的基本条件很重要。可以开展由AM和PM支柱执行的维修活动。Inordertoavoiderrorsdonebyoperatorsormaintenancepeople,whocangeneratetheincreasingofstress,trainingmustbedone.为了避免由能产生压力增加的操作工或维修人员造成的失误，必须要进行培训。Toavoiderrorsduetodesignweaknesses,theEarlyEquipmentManagementpillartakesparttosolvetheissues.为了避免由于设计不足造成的错误，设备初期管理支柱要加入解决此问题。AM:Objectives自主维护：目的Inthefirstphase,theobjectiveoftheAMisthemaintenanceofthe

basicconditionsofthemachinery.Thisisachievableassuringthecorrectoperatingstandardsofthemachinery,thecleanliness,thelubricationandsafety.第一阶段中，AM的目的是维护机器的基本条件。保证正确的机器操作标准，确保清洁，润滑和安全，这是可以实现的。ThefinalscopeoftheAMistostabilizetheconditionsofthemachinery,improvetheirreliabilityandtoobtainasaresultthelengtheningoftheirlifetime.AM的最终目标是稳定机器的条件，改善其可靠性并实现机器使用寿命的延长。Thispresupposesthedefinitionandthecontinuousimprovementofthemaintenancestandardsandtheincreaseofthecompetenciesoftheoperatorsintermsofknowledgeofthemachines.AveryimportanteffectoftheAMisthequalityimprovementofthemachineregardingtheproduct.这预示着维修标准的定义和不断改善，及操作工就机器方面能力的增加。自主维修的一个非常重要的作用是涉及生产的机器质量改善。Initialcleaning&inspection初步清洁和检查Countermeasuresagainstsourcesofcontamination处理污染来源的对策Initialstandards初步标准Generalinspection全面检查Autonomousinspection自主检查Improvementofstandards(workplaceorganization&housekeeping)工作场所组织和设备管理、保养标准的改进Full-scaleapplicationoftheautonomousmaintenancesystem全面贯彻自主维护系统TheSevenStepsofAutonomousMaintenance–AM自主维护的7个步骤Step1Step2Step3Step4Step5Step6Step7The7steps7个步骤Thescopeofthefirstthreestepsistogeneratechangesinthemachines,passingfromconditionsofdirtiness,ofdifficultyincleaningthemachines,hazardousness,slowness,unreliabilityandofbreakdownsandstoppagestoaconditionofcleanliness,safety,reliability,zerostoppagesandzerobreakdowns.前三步是为了改变机器，解决污秽情况及难以清洗的机器问题，将危险，缓慢，不可靠和损坏，停顿情况转变为清洁，安全，可靠，零停顿和零损坏状态。

Thestep2isthemostcriticaloneforobtainingadvantagesthatderivefromAM.Theactivitiesofthefirsttwostepsaretypicallyofareactiveapproach.Theapplicationofsteps1-3istheKEYtodeterminethebasicconditionsofthemachine.第二步是AM取得优势的最关键步骤，前两步是回应方法的典型代表。步骤1到3的运用是决定机器基本状态的关键。The7stepsThefourthandfifthsteparefinalizedtogenerateachangeinthepeople,infacttheinspectionsdonedirectlybytheoperatorscreatescomprehensionandassumptionofresponsibilitytowardswhatandhowtocontrol,eventowardsquality,andmakesworkeasier.Theoperatorsgraduallyassumethecapabilitytoaccomplishautonomouslythemaintenanceactivitiesjustlikeaparentwoulddowiththehealthofhischildrencallingthedoctor,thatcanbecomparedtothemaintenancetechnicianincaseofnecessityforproblemsonthemachinery.It’simportanttoconsiderthefactthattheimplementationofstep4

isexpensiveintermsoftimeandmoney.It’simportanttopayattentiontothecostbenefitofthisstepinordertojustifytheimplementation.Theactivitiesofsteps3-4-5aretypicallyofapreventiveapproach.第4步和第5步是为了改变人，实际上由操作工直接执行的检查创造出对要控制什么，该如何控制及对质量的理解和责任，并且是工作变得更加容易。渐渐地，操作工就有责任，有能力自主完成维修活动，就像父母为了孩子的健康而找医生一样，这可以与万一机器出现问题，必须要找维修技术员相比。就时间和金钱而言，考虑执行步骤4的花费很大很重要。为了证明此步的执行是有效的，注意成本收益很重要。步骤3、4、5是预防性方法的典型代表。Thescopeofthesixthandseventhstepsistogeneratealong-lastingchangeinthemaintenancemanagementacrossanewmanagementsystemofautonomousactivitieswheretheworkerisresponsibleforhisareaintermsofqualityandreliabilityofthemachines.第6步和第7步是为了对维修管理进行长期的改变，形成新的自主活动管理系统，该活动中，工人们负责管理自己区域内的机器的品质和可靠性。Contentsofthe7steps–AM

自主维修的7个步骤的内容StepContentsOfStep步骤的内容0Educationofmachinefunction&condition对机器性能和状态的学习1InitialCleaning&Inspection初步的清洁和检查2Countermeasurestoeliminatesourcesofcontaminationand“hardtoaccess”areas清除污染来源和难以清洗区域的对策3Developprovisionalstandardsforcleaning,lubrication&tightening制定清洗，上油和上紧的临时标准4GeneralInspection–Training&Instructionofthefinalizedstandards全面检查-对最终标准的培训和指导5AutonomousInspection自主检查6Reorganizingworkplace&Standardization重组工作场所并标准化7FullImplementationofAutonomousMaintenance全面贯彻自主维修Motivation动机MachineChange机器改变PeopleChange人员改变WorkplaceChange工作场所改变RestorationofBasicConditions基本状态的恢复PreventionofDeterioration预防磨损OptimizeStandardizeSelfManagement使自身管理最优化，标准化2ELIMINATIONOFCAUSESOFLOSS清除损失原因3STANDARDCLEANINGLUBRICATION标准清洗润滑油4GENERALINSPECTION全面检查5INDEPENDENTINSPECTION独立检查6AREACONTROLANDMANAGEMENT区域控制和管理7COMPLETEAPPLICATIONOFAUTONOMOUSMAINTENANCE自主维护的全面运用INITIALCLEANING初步清洁1THOROUGHELIMINATIONOFDIRTFROMPLANTS对工厂污垢的彻底清除LEARNINGTHAT‘CLEANINGISINSPECTING’学习“清洁就检查”REMOVALOFCAUSESOFDIRT/LOSSES除去污垢/损失原因REMOVALOFOBSTACLESTOACTIVITIES除去阻碍活动的障碍物REDUCTIONOFCLEANING,LUBRICATIONTIMES减少清洁，上油时间DEFINECLEAR,SIMPLECLEANING,LUBRICATION,TIGHTENINGCONTROLSTANDARDS;SPECIFYTIMESANDFREQUENCY定义清洁，简单的清洗；固定控制标准；指定次数和频率IMPROVETHEABILITYTOMAKEAGENERALINSPECTIONOFTHEPLANTACCORDINGTOSTANDARDSANDMANUALS根据标准和指南来提高全面检查工厂的能力IMPROVETHEABILITYTOCARRYOUTINDEPENDENTINSPECTION,PREVENTIVEMAINTENANCECYCLESANDTOUSETHECHECK-LISTS提高执行独立检查，预防性维修周期，使用核对表的能力STANDARDIZEMONITORINGOFTHEEFFICIENCY,OFSTOCKS,QUALITY,对效率，库存和质量的标准华监控IMPROVEDATACOLLECTION;改进数据收集MANAGETHEEQUIPMENTANDTYPECHANGES管理设备，类型改变INTEGRATEDMANAGEMENTOFAUTONOMOUSMAINTENANCEWITHREGARDTOOTHERASPECTSOFTPMANDPURSUITOFCONTINUOUSPERFORMANCEIMPROVEMENTGOALS涉及到TPM其它方面的自主维修的综合管理，追求，完成不断改善目标The7stepsofautonomousmaintenance自主维修的7个步骤Timetable时间表Averagetimeofimplementationofthefirst4stepsofAM自主维护的前4步执行的平均时间0-2nd.Step0-2步3rd.Step第3步ModelArea示范区100days100天1year1年3/6months3到6个月Extensionofthe3rd.Steptoalltheplant将第3步扩展到整个工厂内Implemetationof4th.Steponthemodelarea在示范区执行第4步

PreliminaryactivitiesnecessaryforacorrectdefinitionandimplementationofAM:正确定义和执行AM所必需的初步活动：MatrixCofCostdeploymentanalysisandindividualizationoflossesduetobreakdowns.成本部署分析的C矩阵及由损坏造成的损失的特性Machineclassification机器分类.Targetdefinition:eg.Reductionof90%cleaningtimeonthemodelarea,max1breakdownpermonthonmodelarea,zerobreakdownsonthecriticalmachineduetolackofbasicconditions.目标定义：如，示范区有90%的清洁时间减少，每月示范区最多损坏一次，由于基本条件缺乏的重要机器实现零故障。Individualizationofmodelarea.使示范区个性化Teamcomposition.团队合成PlanningofAMprojects.AM项目的计划Step0–Preparation步骤0-准备Paintshop喷漆车间CabAssemblyTractorAssemblyDrivelineAssemblyStep0–ModelArea步骤0-示范区Trainingoftheoperatorsofthemodelareadonebythemaintenanceguys“theteamleaderandtheoperatorsmustbecomeownersofthemachine”(explainhowthedeteriorationoccurs,diffusetheknowledgeregardingtheimportanceofsafetyduringAMactivities,developknowledgeonhowthemachineworks)andanalysis/executionoffunctionalschemesofthemachines.由维修人员执行的示范区的操作工的培训，“小组领导和操作工一定要成为机器的拥有者”（解释磨损是如何发生的，在自主活动期间，传播安全重要性方面的知识，开发机器是如何运作方面的知识）并分析或实施对机器有作用的计划。PredispositionofallnecessarymaterialsforAM(Rags,detergent,paintbrushes,Tags,formatsfordatacollectionetc.)AM中所有必需材料倾向的状态（碎片，清洁剂，油漆刷，标签，数据收集的版式等）Step0–ModelArea步骤0-示范区Step0–Preparation步骤0-准备Input输入MatrixCofCostDeployment成本部署C矩阵Machinesclassification机器分类Output输出Radarchartoftheteam小组雷达图Masterplanincludingactivitiesforeachstep,auditsandcorrectiveactionsnecessaryforsolvingthecriticalitiesfoundduringtheaudits总体规划，包括每一步的活动，审核和处理危险程度所必需的矫正行为，该危险程度是审核过程中发现的。Team团队-Operators/Maintenancepeople.TheresponsibleoftheteamisthePillarleaderoftheplant操作工/维修人员，团队中的责任人是工厂内的支柱领导。Tools工具OnePointlessonstodeveloptheskillsoftheoperators开发操作工技能的单点课程Radarchart雷达图KPI’s关键业绩指标Know-howachievedbytheoperatorsandmeasuredwiththenumberofOPL’sandwithain-outtestofstep0;由操作工取得的技能并由单点课程数量和步骤零的内外测试进行衡量numberofoperatorsinvolvedinthemodelarea加入示范区的操作工人数Remarks备注OPLonsafetybeforestartingAMactivities开展AM活动前的安全单点课程Fromstep1tostep2foreseeaninvolvementofthePMteaminordertoincreaseandconsolidatetheknowledgeoftheoperatorsregardingtheactivitiesofcleaning,inspection,lubricationandcontrol.为了增加，巩固操作工在清洁，检查，上油和控制方面的知识，步骤1到步骤2预知有PM团队加入。Step1–InitialCleaning步骤1-初步清洁Initialcleaningandinspectioninordertoremovedustanddirtthatarethesourcesofdeteriorationofthemachines.为了除去灰尘和污垢，要进行初步的检查，此灰尘和污垢是机器磨损的来源。Removedustanddirtofallthepartsofthemachine.除去机器上所有零件上的灰尘和污垢。Hangtagsonthemachineshowingalltheanomalies,sourcesofcontamination,hardaccesszoneswhichcancausequalitydefects.在机器上挂上标签，展示出可能造成质量缺陷的所有的异物，污染来源，硬的接触区。Removealluselessobjectsandcreatetidinessandcleanliness.移走所有无用的东西，创造整洁，清洁的环境。Writethelistofanomalies记下异物清单

...CLEANINGISINSPECTING清洁就是检查MACHINECLEANED清洁的机器DIRTISREMOVED,CHIPS,SCRAPSAREREMOVED除去了污垢，碎片，废料THEELEMENTSOFTHEMACHINERYARETOUCHEDWEARANDDOWNGRADINGISPREVENTED预防了磨损和降格THEPLANTISKNOWN工厂被大家所知IRREGULARFUNCTIONINGISIDENTIFIED不规则的机能已被鉴定WEARISCHECKED磨损已被检查PREVENTION预防useman’s5sensesAppropriately适当地使用人的5种感觉Step1–InitialCleaning步骤1-初步清洁Operatorslearnthatcleaningisinspection…操作工学习清洁就是检查…improvingtheirabilitytotraceminorproblemsandtodiscoverirregularitiesduringcleaning在清洁期间，提高追踪小问题，发现不整齐东西的能力。AimsofInitialcleaning初步清洁的目标Step1:InitialCleaning步骤1：初步清洁I'llstarttocleanwitharagIhavealsogottoinspecttheinsidetheofmachine

Toomuchgrease!

Thecover’smissing!

Theoillevelisn’tvisible!

Too

muchdirt

andnotenoughgrease

Excessleakageofoil

Thisway,

I’lltraceallthefaults!

ThepressureisOK

Continuoustagging不停的加标签Indicationofissueoftag指出标签上的问题Shortcircuitduetosimpleproblems小问题造成的短路Repetitive(chronic)Causesunknown反复出现的（长期的）未知原因Listoftags标签清单Tagsattached附上的标签Tagsremoved去掉的标签Action行动SolvingoftheProblem问题的解决TeamLeader+BTULeader+GroupTeamLeader+BTULeader+Maintenance+Aut.Maint.Resp.Step1:initialcleaning步骤1：初步清洁

Step1–InitialCleaning步骤1-初步清洁Inthisphasetheoperators,afterreceivingthetrainingonsafety,howtoclean,whichtoolstousefortheactivitiesandhowtopayattentioninordernottocreatedamagestothemachine,theycanstarttheinitialcleaning.It’simportanttoremoveallthedirt,findalldefects,anomaliesandhiddenbrokenthingsplacingAMtagswheretheproblemsare.为了不给机器带来损坏，此阶段中的操作工在受到安全，怎样清洗，活动中使用哪种工具，如何注意培训后，他们可以开始进行清洗了。除去贴上AM标签地方的所有污垢，找出所有缺陷，异物和隐藏的损坏东西很重要。BeforeAfterBefore之前After之后

Step1–InitialCleaning步骤1-初步清洁

Step1–InitialCleaning步骤1-初步清洁Output输出

Listofalltheanomaliesassigningresponsibilitiesanddeadlines.列出所有的异物，指明归属责任和截止时间Quantificationofcostbenefitsofthestep量化此步中的成本收益Suggestions建议Hoursoftrainingand/orOPL’s培训和/或单点课程的时间PlanofAMactivitiesforcleaningAM清洁活动的计划Team团队TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.AtthelaunchofthefirstAMactivity,it’srecommendablethattheplantmanagerispresentandactivelyparticipates,tocreateinvolvementandtogivetherightcommitment.此活动中包括了示范区内的所有操作工，由支柱领导指导。第一个AM活动开展时，可以推荐厂长出席并积极参加，呼吁人们参加并给出适当的评论。Tools工具AMtagsmustbeusedplacingthemneartheindividualizedanomaliesorcanbeusedtosuggestanimprovement.AM标签可被放在个别异物旁或被用于提出改善建议。TheAMtags,usually,areblueifsolvedbyoperatorsandredifsolvedbymaintenancepeople.该AM标签若是由操作工解决的就是蓝色，若是维修人员解决的就是红色。KPI’s

关键业绩指标

NumberofAMtagsperweek(considerthatforanaveragecomplexmachine,thenumberoftagsaftertwo/threeweeksofactivitiesofcleaningandinspectioninordertobeconsideredasuccess,itshouldbearound300/400tags.)每周的AM标签数（对于复杂程度一般的机器，考虑其2到3周的清洁检查活动后的标签数量，为了成功，标签数应为300到400左右。）Implementationrate(Tags)执行比率（标签）Numberofquickkaizens快速改善数量Savingsontechnicalcleanings技术清洁方面的节省Regardingthecalendar:hrs/week,hrs/weekofovertimeforAMactivities关于记录表：AM活动超时的时间（小时/周）Remarks备注Organizetheactivitieswithoutinterferencewithproductionorganizingthestoppagesororganizingwhenthemachinesarestopped(nightshift,Saturdays,Sundays)组织停产活动，组织停顿或在机器停止时组织（夜班，周六，周日）Assuremaximuminvolvementofthepeopleontheshopfloor:e.g.Paintingthefloorofthemodelareawhitesothateveryonecan“see”thesourcesofdirtandsothateveryoneunderstandstheresponsibilityofkeepingtheworkplaceclean.确保车间人数最大量的参加：如，将示范区喷为白色，以便大家都能看到污垢来源，并让大家明白保持工作场所清洁的义务。Godeepintheanalysisofeachcomponenttounderstandthenecessitytolubricateeveninvolvingthevendor.Weareusuallyconvincedthatwhatwelubricateisenoughbutifwegoindetailwefindoutthatthere

ismanyotherthingstolubricate.深入分析每个零件，明白上油的必要性，即便是联系卖方。通常我们都相信我们所上的油足够了，但是再仔细看来，还有许多其它东西要上油Step2–Countermeasuresagainstsourcesofcontamination步骤2-清除污染来源的对策Individualizethesourcesofcontaminationandthehardaccesszones.个别加以考虑污染来源和硬的接触区Findcountermeasuresforthesourcesofcontaminationandthehardaccesszones.找出污染来源和硬接触区对策。Reducetimeforcleaning,inspectionandlubrication.清洁，检查和上油的时间减少。Step2–countermeasuresagainstsourcesofcontamination步骤2-清除污染来源的对策‘Platecover’Lowcost,easytoapply成本低，易于应用‘Boxtype’Lowcost,veryEffective成本低，很有效Changethematerialtoplastic,rubberorsheetsteel将材料变成塑料制品，橡胶或钢板Step2–Countermeasuresagainstsourcesofcontamination步骤2-清除污染来源的对策Before之前After之后Installationoftraytocollectchipsandoilfrommachining安装托盘来收集加工时漏出的碎片和油Contaminationwithchipsandoilfrommachinedparts机械零件上的碎片和油渍污染CleaningTimeReduction清洁时间的减少Machine:COMAUTransferLine Area:GearBox机器：COMAU传递线区域：传动箱Before之前After之后Otherresults:其它结果：CleaningTime(Minutes/day)Problem:difficultaccessduetotheshapeofthecovers问题：由于盖子的形状而难以接近Countermeasure:installationofmeshcoverswithsafetydevices对策：安装安全装置-网状盖子-53%EXAMPLEStep2–Countermeasuresagainstsourcesofcontamination步骤2-清除污染来源的对策Extensionto6similartransfermachines延伸至6种类似的转移机器-Eliminationoffloorslickness消除地板的光滑Step2–Countermeasuresagainstsourcesofcontamination–ActionPlan步骤2-清除污染来源的对策-行动计划Step2–Countermeasuresagainstsourcesofcontamination步骤2-清除污染来源的对策Step2–Countermeasuresagainstsourcesofcontamination步骤2-清除污染来源的对策Output输出Listofallthesourcesofcontaminationandcountermeasuresfortheirtheelimination.列出所有的污染来源并找出相应的清除对策Team团队-TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.该活动包括示范区的所有操作工，且由支柱领导指导。Tools工具-Quickkaizens:PDCAactivitiesofproblemsolving快速改善：解决问题的PDCA活动KPI’s关键业绩指标Numberofimplementedcountermeasuresindividualized.个别加以考虑的对策的实施数量Cleaningtimereduction清洁时间的减少Lubricationtimereduction.上油时间的减少Inspectiontimereduction.检查时间的减少Costbenefitanalysisofthestep.此步的成本收益分析Breakdowntrendonthecriticalmachines重要机器的损坏趋势Remarks备注Inthecostbenefitanalysis,takeinconsiderationalsothereductionofthecleaningtimeofthetechnicalcleaningsexecutedbyexternalcontractors.在成本收益分析中，也考虑由外商执行的技术清洁时间的减少。Calculatealsothesavingscomingfromthereductionofmaterialsandenergydirectlylinkedwiththesourcesofcontamination(eg.Oilecc.)也计算直接联系到污染来源的材料和能源的减少。（如：油等）Step3–Initialstandards步骤3-初步标准Createinitialstandardsforcleaning,inspection,lubrication,tightenings,visualcontrols,thatallowtheoperationswithlesstimeandefforts(specificatingwhichpartofthemachine,time,frequency,gaugesettingmanagement,assignementoftasksandresponsibilities.为清洁，检查，上油，固定，可视化控制创建初步标准，用较少的时间和努力进行操作，指明机器的某个部分，时间，频率，设置管理的标准尺，任务和责任的分配。Improvetheeffectivenessofthestandardsintroducingvisualmanagement.

提高介绍可视化管理标准的有效性。Reducetozeroallbreakdownsduetolackofbasicconditions(lackofAM)ofthecriticalmachines.将由于关键机器缺乏基本条件（缺乏自主维修）造成的故障减为零。Problem问题

ONEPOINTLESSON(OPL)单点课程Comp.by:…..Dateoftraining培训日期Trainer培训者Pupil学生Improvement改善

Date:15/07/03Basicknowledge基本知识Topic:FLOWMETERS–visualcontrolofoperatingrange话题：流动表-操作范围的可视化的控制Plant:M.F.O.U.:ENGINESBTU:105OP.110SAIMPGRINDINGaOperatingrangehighlightedwithindicationinred(incorrectoperatingrange)andgreen(correctoperatingrange)用红色突出不正确的操作范围，绿色突出正确的操作范围Signature签名:INCORRECTOPERATINGRANGE不适当的操作范围CORRECTOPERATINGRANGE正确的操作范围No.17exampleStep3–Initialstandards步骤3-初步标准Markmostimportantboltssoastoimmediatelydetect,withaninspection,anyloosening(whentheboltisloosethepaintlineissectioned)标记最重要的螺栓以便立即进行检查出一切松动（当螺栓松动时，油漆线就会被截成段）Makethemachineseasytoinspect使机器易于检查Step3:defineinspection,cleaningandlubricationstandards

步骤3：定义检查，清洁和上油标准Vibration振动Temperature温度Visualcontrolreducesthetimenecessaryforinspectingerrors可视化控制减少检查错误的必要时间Numberofbelts带子的数量Wear,dirt,dust磨损，污垢，灰尘Tension张力1.MAKEHIDDENINSPECTIONPOINTSVISIBLE使隐藏的检查点可视化2. LOCATEINSPECTIONPOINTS ATEYEHEIGHT以视觉高度定位查找检查点MAKEHIDDENPARTS VISIBLE使隐藏零件可视化Step3:defineinspection,cleaningandlubricationstandards步骤3：定义检查，清洁和上油标准Improvementofvisualcontrol可视化控制的改善Improveplantvisibilityinordertofacilitatemaintenance:为了便于维修，提高工厂的可视性：Usecolorsandlabels用颜色和标签Displayfluidlevels显示液面高度Makebeltandgearmovementsvisible使运输带和齿轮运转可视化Displaytemperatures,operatingranges,flowsofcoolants,etc.显示出温度，操作范围，冷却液的流动等。BEFORE之前AFTER之后GEARMOTORSARMASBTU6DIFFICULTTOCHECKCORRECTOILLEVELINGEAREDMOTOR很难检查减速电机中正确的油位FAST,SAFECHECKINGOFCORRECTOILLEVEL对油位的准快速，安全检查Step3:defineinspection,cleaningandlubricationstandards

步骤3：定义检查，清洁和上油标准D=DailyW=Weekly(Saturday)M=MonthlyBM=every2monthsSM=every6monthsA=AnnualDEPT.09PAGE1OF2INSTRUC.:MBU1030REV.:00of09.02.96ISSUEDBY:APPR.:AUTONOMOUSMAINTENANCEPLANMACHINE:CL.L.SAIMP-FORRESTTG.3830PROCESS:REDUCT.BOX/SEMISC.RINVIICleaningoftooltrolley清洗工具车Cleaningofareainsidemachine清洗机内地方Cleaningofwatertank清洗水箱Cleaningofpallet清洗托盘Cleaninginsidetoolcribandoutside清洗工具箱内外ReadingscaleaxisX-Y–Z阅读比例轴XYZReplaceoilfilter+centraloilcartr.ReplaceoilcoolingairfilterFilter,electricalcabinetCheckonreadingscaleChecktach.dyn.brushes,motorsCheckefficientgroundconnectionCheckmotortake-offYaxisCleaninsideelectricalpanelCheckelec.andoverrunlimitswitchesReplacementspindlemotorfiltersINSPECTIONCLEANINGElim.dirtandchipsElim.dirtandchips-EliminatechipsPreventleaks–gen.cleaningAvoidcorrosionPreventmachinestoppagePreventmachinestoppageImprovesuctionAvoidreadingerrorsPreventmachinestoppageSafetySafetyPreventmachinestoppageSafetyMachinesafetyAircompr.suct./pist.Brush-shove.BrushAspireliquidsBrushorsuctiondeviceRagsandliquidDegr.scalew.alcoholReplaceReplaceReplaceVisualEmerypaper.+sprayTesterAmmeterRagsandsolventBlowingandsprayWrench,etc.WWSMWSMSMATMMSMSMSMSMSMSMSMOperat.Operat.CompanyOperat.2oper.Maint.Maint.Maint.Operat.Maint.Maint.Maint.Maint.Maint.Maint.Maint.YESYESYESYESYESYESYESYESYESYESYESYESYESYESYESYES2525-17400(200)(60)(30)(15)(60)(180)(15)(60)(30)(60)(45)WHATWHYHOWWHENWHOM.st.mM.washTimeExampleStep3:defineinspection,cleaningandlubricationstandards步骤3：定义检查，清洁和上油标准Step3–Initialstandards步骤3-初步标准Output输出

Autonomousmaintenancestandard/plan.Contains:thenameofthemachine,thecomponentsubdivision,thecleaningstandard,inspectionandlubricationforeachcomponent,themethodsandthetoolstoutilize,thefrequency,theresponsibility,thedailyplan(it’simportantthatthedetailsoftheplanaredailyandnotweeklyandthatontheplanarewrittenonlythebreakdownsthatareduetolackofbasicconditions(lackofAM).自主维修标准/计划，包含：机器名称，零件细分，清洁标准，每个零件的检查和上油，使用方法和工具，频率，责任，日常计划（重要的是计划的细节是日常的不每周的，计划中仅记下由于基本条件缺乏（自主维修缺乏）造成的故障）Team团队-TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.这项活动涉及到示范区所有的操作者并由支柱领导指导。Tools工具-OPL,SOP,AMplan单点课程，标准操作程序，自主维修KPI’s关键业绩指标

Costbenefitsofthestandards/plan标准/计划的成本收益Costbenefitsoftheactivitiesdonefromstep0tostep3步骤0到步骤3内执行活动的成本收益Breakdowntrendonthecriticalmachines.关键设备上的损坏趋势Remarks备注Inordertoevaluatethecost/benefitsoftheactivitiesdonefromstep0tostep3it’snecessaryto:为了评估步骤0到3的活动的成本/收益，必须要：Verify,foreachmachineunderAM,theeconomicallossreductionimprovementsignalizedbyCostDeployment;核实每个自主维修下的机器的由成本部署指出的经济损失减少改善Consolidatethesavingsofthetechnicalcleaningsexecutedbyexternalcontractors;巩固由外商执行的技术清洁节省Defineandcalculatethehoursofmaintenancemanpowersavedbytransferringthecleaning,inspectionandlubricationstandardstotheoperators;定义并计算人力维修时间，这些时间是将清洁，检查和上油标准转移给操作工节省的CalculatethecostsofAMintermsofmanpower,machinestoppages,tools,materialsandtraining;就人力，机器故障，工具，材料和培训计算自主维修成本SpecificAMmachineclassificationofthemachinesandcomponents(AA,A,B,C),includeintheclassificationthedataregardingbreakdownsduetolackofbasicconditionsthataresignalizedontheAMplan.机器和零件的具体自主维修机器分类(AA,A,B,C)，包括关于由于基本条件缺乏造成的故障的分类数据，这些基本条件是AM指出的。Step4–GeneralInspection步骤4-全面检查Theobjectiveofthefirstthreestepsistoavoidthedeteriorationofthemachineryandthemaintenanceofthebasicconditions(cleaning,inspectionandlubrication).前三步的目标是为了避免机器磨损和维修基本条件（清洁，检查和上油）Step4isfundamentalforthetrainingoftheoperatorsonthetechnicalcharacteristicsofthemachines,inordertoincreasetheirabilityofdiscoveringthemalfunctioningsand,withthehelpofthespecialists,elaborateageneral

inspectionplan.Inthisstepthetrainingregardingqualityaspectsofthemachineandoftheproduct,intermsofparametersofthemachinethatcaninfluencethequality,isalsoimportant

.第四步是操作者对机器的技术特性的培训基础，为了增加他们发现故障的能力，在专家的帮助下，阐述了一种全面检查计划。此步中的关于机器和产品质量方面的培训也是很重要的，机器参数同样也影响质量。Step4–Activities(1/2)步骤4-活动(1/2)

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