第六章 全面生产维护

TotalProductiveMaintenance(TPM)

全面生产维护（TPM）TPM–DefinitionTotalProductiveMaintenance(TPM)isamanufacturinginitiativeforoptimizingtheeffectivenessofequipment全面生产维护（TPM）是制造过程中优化设备效率的管理方法FiveComponentsofTPM

TPM的5个组成部分Maintenanceprevention:design/selectionofthemachineforoptimumperformanceandlife1.保养预防：设计/选择机器优化性能和寿命2.Predictivemaintenance:predictingthelifeofcriticalmachinecomponentsandreplacingthem2.预测性维护：预测关键设备零部件的寿命并更换它们Correctivemaintenance:improvingtheequipment’sdesign/systemstogetbetterperformance3.校正性维护：改善机器的设计/系统以获得更佳的性能Preventivemaintenance:throughplannedmaintenanceactivitiesensuringcontinuous,smoothperformance4.预防性维护：通过计划维护工作确保持续的、平稳的性能Autonomousmaintenance:employeeownedcompletemaintenanceprogram5.自主维护：职工拥有完全的维护程序5.AutonomousMaintenance

5.自主维护Objective:makethemachineoperatorthe“firstlineofdefense”,throughtrainingandempowermenttoensureregularcleaning,lubrication,inspectionsandtotalownershipthatachievescontinuousimprovementinequipmenteffectiveness目的：通过培训和授权让机器的操作者成为“第一道防线”，确保定期的清扫、润滑、检查和全部所有权，以获得设备效率的持续改进。Autonomousmaintenanceisself-governing,self-ruling,non-centralizedmachinemaintenanceprogram自主维护是一种自我管理、自我控制、非集中的机器维护程序。Requiresthebiggestchangeinattitudesofall需要下列人员在态度上发上极大的改变：Management,maintenancetechnicians,machineoperators,engineers管理人员、维护技术员、机器操作者、工程师WhyAutonomous?

为什么是自主的？Operators操作者Spendthemosttimewiththemachines其与机器度过大多数时间CANandWILLnoticetheabnormalitiesfirst能够并且会第一时间注意到异常现象Havethemostuniqueknowledgeofthemachine,it’spartsandit’sfunctioning对机器、其零件和功能拥有大多数独一无二的知识Havemuchcloseremotionalattachmentwith,andsenseofownershipofthemachines对机器有主人翁责任感，具有更为亲近的感情Livelihooddependsmoredirectlyonthemachineinquestion其生活更直接地依赖于所述的机器Aremostlytechnicallyinclined主要是倾向于技术WhyAutonomous?

为什么是自主的？“someonewhoisdrivingacardailywillnoticeafaultyfront-endalignmentmuchsoonerthanthemechanicwholooksatitoccasionally”“每天都开车的人将会比一位只是偶尔查看这辆车的技师更早注意到有缺”WhatIsTPM?Optimizeeffectivenessofmachinesby通过下列工作优化机器的效率：Focusingonentirelifeofthemachine关注机器的全部使用年限Involvingallthecontributorsthroughactiveparticipationandteaming通过主动参与和组成团队，涉及到所有有贡献的人Makingtheoperatorsthefirstlineofdefenseagainstdeterioration,throughAutonomousMaintenance通过自主维护，使操作者成为防止机器退化的第一道防线SettingthegoalofZeroLosses设定零损失的目标InOtherWords….Doeverythingpossibletomakesurethemachinekeepsmakinggoodqualityparts,atthedesiredproductionrate,everytimeyouwantitto尽可能做好每一件事情，确保机器在你要求的每时每刻按照要求的生产速度持续不断的生产优质零件OR或者Zerobreakdowns零故障 Zerodefects零缺陷 Zerolossesduetosetups 调试造成的损失为零Zeroaccidents 零事故 Zeroleaks零泄漏 SevenStepsof

TotalProductiveMaintenancePerforminitialcleaning&inspection实施初始清扫&检查Eliminatecausesofcontamination&inaccessibleareas消除污染源和不可接近的区域Developcleaning,lubricating,andinspectionstandards制定清扫、润滑和检查标准Providebasictraininginmachine’sfunctionandcontrols,toenableeffectivegeneralinspection提供关于机器功能和控制的基本培训，使其能够行使有效的全面检查Enhanceandimplementautonomousinspectionstandards&schedules提高并执行自主检查标准&时间进度表Implementworkplaceorganization&housekeeping,employing5S&visualcontrols运用5S和可视控制贯彻执行工作场所组织&内务管理Followuponalltheabovestepsandadvancedimprovementactivities遵守上述全部步骤和预先的改进工作TPMStatusWheel

TPM状态轮StagesofTPMEquipmentEffectiveness设备的效率Time时间RestorationTPM重建TPMSustainingTPM持续的TPMUsefulLifeofEquipment设备的使用年限TPMSteps4-7TPM的第四步至第七步InitialTPMKaizenEvent初始的TPM改善活动TPMSteps1,2,3TPM的第一、二、三步RestoretheMachinePrepareforSustainingSustainSevenStepsof

TotalProductiveMaintenancePerforminitialcleaning&inspection实施初始清扫&检查Eliminatecausesofcontamination&inaccessibleareas消除污染源和不可接近的区域Developcleaning,lubricating,andinspectionstandards制定清扫、润滑和检查标准Providebasictraininginmachine’sfunctionandcontrols,toenableeffectivegeneralinspection提供关于机器功能和控制的基本培训，使其能够行使有效的全面检查Enhanceandimplementautonomousinspectionstandards&schedules提高并执行自主检查标准&时间进度表Implementworkplaceorganization&housekeeping,employing5S&visualcontrols运用5S和可视控制贯彻执行工作场所组织&内务管理Followuponalltheabovestepsandadvancedimprovementactivities遵守上述全部步骤和预先的改进工作ObjectivesofStep1Cleantheentiremachine–insideandout清扫整台机器——内部和外部Inspectforproblems,abnormalitiesanywhereinthemachine检查机器是否存在问题和异常现象Identifyopportunitiesforimprovements/enhancementstotheoriginaldesign确认对初始设计的改进/提高机会Identifytheroutinecleaning&inspectionneeds确认日常的清扫&检查需要Operators&maintenancepersonnellearn操作员&维护人员知晓下列事项Howtothoroughlyclean&inspectwhilecleaning在清扫时，怎样彻底清扫&检查Howtoidentifyproblems,abnormalities怎样确认存在的问题和异常现象Todevelopstandardsforroutineactivities制定日常工作标准Cleaning

清扫Cleanalltheoutsidesurfacestouncoverabnormalities清扫所有的外表面以发现异常现象Disassembleallthesystemsandcomponentstothoroughlycleanandinspecteverycomponent拆卸所有的系统和零部件，对每个零部件进行彻底的清扫和检查Removealltheauxiliarysystemsandcomponentstoclean&identifyopportunitiesforimprovements拆除所有的辅助系统和零部件进行清扫&确认改进的机会Pressurewash(withhotwater)allthecomponents（使用热水）压力清洗所有的零部件Prepareappropriatesurfacesforrepainting适当的表面重新涂漆Understandwhichpartsofthemachineneedtobecleanedonaroutinebasisandhowoften了解机器的哪些零件需要日常清扫以及清扫的频率Inspections检查Lookforleakageof检查下列事项是否存在渗漏Lubricants,coolants,hydraulicfluids,air润滑器、冷却剂、液压油、空气Checktheconditionof检查下列事项的状况Belts,chains,couplings,motors,gearboxes,etc.传动带、传动链、连接、发动机、齿轮箱等Electricalpneumatic,hydraulicandcoolantsystemcomponents电气、液压和冷却系统零部件Allthefasteners所有大紧固器Alltypesoffilters,valves,regulators,gages,indicators,etc.所有类型的过滤器、阀、调节器、量具、指示器等Lookfor查找Excessivevibrations,noise,heat过度的振动、过度的噪音、过热Lookfor查找Excessive,insufficient,orlackoflubrication润滑过度、润滑不足，或者缺少润滑Abnormalities异常现象Anythingthatispresentwhereitdoesnotbelong出现的任何不属于下列事物的事项Coolant,oil,grease,chips,swarf冷却剂、油、润滑脂、碎屑、细铁屑Tools,accessories,setupparts,productionparts,etc.工具、附件、安装零件、生产零件等Coffeecups,rags,papers,drawings,Kanbancards,etc.咖啡杯、地毯、纸张、图纸、看板卡等Anythingthatisabsentthatshouldbepresent应该出现而缺少的事项Lubricants,fasteners,guards,covers,brackets,etc.润滑剂、紧固器、防护罩、端盖、支架等Worn,broken,missing,malfunctioningparts/systems磨损、破碎、丢失、不正常工作的零件/系统Wearonslidingsurfaces滑动表面的磨损Play,looseness,sagging,excessivemovements游隙、松动、下垂、过度运动Warpage,deformation,misalignments翘曲、变形、未校准Rustorsurfacedamage生锈或表面损坏Odor,stains,discolorationofanyliquids液体的臭味、污点和变色Lubrication–OilingSystems润滑——上油系统Identifysourcesofleakage确认渗漏源Emptyandcleanthetank,andallthelines倒空并清扫油槽及整个管路Cleanorreplacefilters清扫或更换过滤器Makesurelubricationlinesarenotdamagedorclogged确保润滑管路没有遭到损坏或堵塞Verifythatallpointsarereceivingoil,inproperquantity验证所有的润滑点均受到适量润滑油的润滑Makesurepressurizingsystemisworkingproperly确保加压系统正常工作Makesureallthegages,indicatorsareworking确保所有的量具、指示器均在工作Considerappropriatenessoftheirlocation考虑它们位置的适当性Getre-circulatingoilanalyzedtouncovercontamination,over-heating,spoilageandcauses获取再循环润滑油以发现污染、过热、损坏及其起因Verifyappropriatenessofthelubricantsused校验所使用的润滑剂的适当性ObjectivesofStep2

第二步的目的Preventaccelerateddeteriorationbystoppingthecontaminantsattheirsource&preventintroductionofcontamination从源头上阻止污染物，以及防止污染的进入防止加速损坏Learnaboutequipmentimprovementactivities了解设备改进工作Makethoroughcleaningandinspectioneasierandlesstime-consuming使全面的清扫和检查工作更易于进行并节省时间Focusonobstaclestoeffectivecleaning&inspection集中精力于那些有效清扫&检查的障碍Encourageoperatorstousetheircreativitytocontrolequipmentandtheenvironmental鼓励操作员运用他们的创造性来控制设备和环境Encourageproactiveapproach鼓励主动方法ObjectivesofStep2Eliminateallthedrippans消灭所有的承油盘TypicalContaminants

典型的污染物Leakageorsplatteringoflubricationorhydraulicoils,grease,coolant,water,air,otherliquids润滑油或液压油、润滑脂、冷却剂、水、空气、其它液体渗漏Cuttingchips,grindingswarf,drygrindingpowder,punchedsheetmetalpieces,cuttingorweldingsplatters,spraypaint,moldingflash,looseburrs,sandfromcastings切屑碎屑、研磨碎屑、干的研磨粉、冲下的金属碎片、切屑或焊接飞溅物、喷漆、模制飞边、没有约束的飞边、铸造产生的砂子Otherforeignmatters–dust,packingmaterial,mist,moisture,smallcomponents,brokenparts,fasteners,excessglueoradhesives其它异物——灰尘、包装材料、烟雾、湿气、小部件、破损的零件、紧固器、过量的胶水和粘结剂EliminatingContamination

消除污染Repairleaks,preventoverflows维修渗漏，防止溢流Reduce/controlflowofallthefluids减少/控制所有液体的流出Installshieldsandcoverstocontaincuttingdebris安装防护罩和端盖容纳切屑碎片Containthedebristoassmallspaceaspossible容纳碎片的空间越小越好Installdirtanddebriscollectors安装灰尘和碎片收集器Automaticchips/swarfconveyingsystems自动的碎屑/切削屑输送系统Poweredmistanddustcollectorsformachines为机器安装有动力装置的烟雾和灰尘收集器Usevacuuminsteadofpressurizedairforcleaning进行清扫工作时，使用真空吸尘器替代压缩空气Deviseefficientcleaningandwashingmethods设计高效的清扫和清洗方法Considerreplacingalltheseals,wipers,fasteners,bearings,andotherlowcostspares考虑更换所有的密封、垫圈、紧固器、轴承和其它低成本备件CausesofInaccessibility不可接近的起因

HiddenLocations隐藏的位置Behindthemachine,behindthecovers处在机器的背后、端盖的背后Obscuredbyotherparts,hoses,pipes,cables,controlpanels,auxiliaryequipment被其它零件、软管、电缆、控制面板、附属设备所遮蔽Obscuredbystoragecabinets,partsstorage,othermachines,etc.被储藏室、零件仓库、其它机器等所遮蔽Coveredupbychips,swarf,dust,paint,etc.被碎屑、切削屑、灰尘、油漆等所覆盖Movingpartshavetobealignedinacertainway运动零件必需以某种方式校直CausesofInaccessibility不可接近的起因

DifficultLocations不利的位置Exposuretoinjuryorhazards,suchaschipsorsharpobjects暴露于受伤害或危险之中，例如碎屑或尖锐的物体Exposuretoslippinghazards,suchasoilyorwetfloors暴露于滑倒的危险之中，例如含油的或潮湿的地面Possibilityofexposuretoelectricshock,highpressure,hightemperature有暴露于电击、高压、高温的可能性Highupfromthefloorortooclosetothefloor距离地面过高，或距离地面过近Smallpassageforoperatororhandsortools对于操作者或手或工具来讲，过小的过道ImprovingAccessibility提高接近性Repositiongages,indicators,lubricationpoints量具、指示器、润滑点复位Installconsolidatedlubricationsystems安装统一的润滑系统Reroutepipes,hoses,cables管路、软管、电缆重新布线Avoidflexiblehosesandcableswhereverpossible尽可能的避免使用有弹性的软管和电缆Addtransparentwindowsoncovers在端盖上添加透明的窗户PolycarbonateorLexan聚碳酸脂或勒克森Simplifycovermountingsforquickremoval简化端盖安装，便于快速拆除Removedrippansandplatforms拆除承油盘和平台Providesufficientspacebetweenmachines机器之间有足够的间隙TargetsforImprovement

改进的目标Machinepartsthatgetdirtysoonafterthoroughcleaning在彻底清洗后很快就变脏的机器零件Timespentinroutinecleaningisdisproportionatelyhigh花费在常规清扫上的时间不成比例的高Keypartsofmachinethatarehardorimpossibletocleanandinspect机器的关键零件难以或不可能进行清扫和检查Cleaningorinspectionishazardous清扫或检查工作时是危险的ObjectivesofStep3Capturetheknowledgeandunderstandingacquiredbytheoperatorsandmaintenancetechnicians获取作为操作员和维护技术于所需的知识和认识Developprovisionalstandardsforcleaning,inspectionandlubrication制定清扫、检查和润滑的临时标准Organizetheworkarea&machineandplacevisualcontrolstohelpfollowstandardsefficiently组织工作区/机器和场地视觉控制，帮助有效地遵守标准Organizecleaningandlubricationsupplies,tools,etc.组织清扫和润滑供应品、工具等Beginimplementingthepracticesthatwillhelpmaintainequipment’sconditionachievedinsteps1and2开始实施那些有助于维护设备在步骤1和步骤2中取得的状态的实践ProvisionalCleaningStandards临时清扫标准CleaningstandardsshouldInclude清扫标准应该包括：Areas/parts/systemstoclean要进行清扫的区域/零件/系统Scheduleforcleaning清扫的时间进度表Methodofcleaningandtoolstobeused将要采用的清扫方法和工具Acceptancecriteriaforcleanliness清扫工作的验收标准Organizethecleaningsupplies,placeconvenientlyandlabelthem组织清扫用品，放置到方便的位置，并为它们加上标签Makeassignmentsamongtheoperators在操作员之间分派工作Tryoutthestandardsandtimethem试用该标准并为其定时Identifyopportunitiesandneedsforimprovements确认改进的机会和需要GuidelinesforProvisionalStandards临时标准指导原则Standardsmustbedevelopedbytheteamwithveryactiveparticipationoftheoperators标准必需由团队制定，并有操作员的积极参与Non-participatingoperatorsofthemachinemustreviewprovisionalstandardsbeforeimplementation没有参与其中的机器操作员必需在实施之前审查临时标准Listthetasksinalogical,efficientsequence按照逻辑的、有效的顺序列出工作任务Standardsshouldbeclearandeasytounderstand标准应该是清楚的、易懂的Labelsonthemachineandchecklistsmustmatch机器上的标签和检查单必需相配比Tryoutthestandardsto使用该标准Verifyappropriatenessandsafetyofthetasks校验任务的适合性与安全性Verifyoperatorcapabilityandskills校验操作者的能力和技术Timeeachtasktoidentifyimprovementopportunities为每项任务定时以确认改进机会ObjectivesofStep4Enhanceoperator’sknowledge&skillsrelatedtoequipment’soperation,systemsandcomponents提高操作者对设备操作、系统和零部件有关的知识和技能Improveinspectionanddiagnosticskills提高检查和诊断的技能Expandthescopeofroutineinspectionperformedbytheoperators扩展由操作人员履行的日常检查工作的范围Promotecontinuousimprovementthroughcorrective&predictivemaintenance通过纠正&预先维护工作激励持续的改进Makesurethereisacommon“language”andterminologythroughouttheorganization确保在整个组织中使用通用的“语言”和术语ActivitiesDuringStep4Identifytrainingtopics确认培训的主题Identify/developtrainingmaterialandmethods确认/制定培训材料和方法Evaluatethepotentialtrainerresourcesandselect评价潜在的培训师资源并作出选择Developamasterplanfortrainingdelivery为培训交付制定一个总体规划Providethetraining提供培训Evaluatethetrainingperformanceandmakenecessarychanges评价培训成绩，并作出必要的改变Periodicallyreevaluatethetrainingneeds周期性地重新评价培训需要Includeappropriatetopicsinnewemployeetraining在新员工培训中包含适当的主题ExpectedOutcomeofIndividualTraining

个体培训期望得到的结果Operatorsunderstandthespecificsysteminvolvedinthemachineandit’sfunction操作者理解包括在机器中的特定系统及其功能Operatorscanidentifykeycomponentsofthesystemandtheirfunctions操作者能够辨别系统的关键零部件及其功能Operatorscancleanandinspectthesystemandallthecomponents操作者能够清扫并检查系统及所有零部件Operatorsbecomeawareofcommonlyoccurringproblemsandrecognizesymptomsofmalfunction操作者开始了解通常情况下发生的问题，能够认出故障的现象Becomeawareofimmediateactionstobetaken,inasafemanner,whenabnormalitiesareidentified当确认发生异常情况时，知晓以安全的方式立即采取的行动Explainthesymptomstomaintenancetechnicians向维护工程师说明现象Operatorscanthinkofimprovementopportunitiesandideas操作者能够考虑到改进机会和想法ObjectivesofStep5

第五步的目的Updateandfinalizetheprovisionalstandardsdevelopedduringstep3更新并最终确定第三步中制定的临时标准maintenanceandaudits维护和审查Developandinstitutionalizeimprovement/updateprocessforthestandards制定标准的改进/更新程序，并使其制度化Combinecleaning,lubrication,andinspectiontasksinto“unifiedautonomousmaintenancestandards”使清扫、润滑和检查工作联合成为“统一的自主维护标准”Substantiallyreducethetimetakenforcleaning,lubricationandinspectionactivities大量减少进行清扫、润滑和检查工作所需的时间ObjectivesofStep6

第六步的目的Maintaintheareasurroundingthemachinecleanandorganized,atalltimes,tosupportthedisciplinedTPMactivities保持机器周围区域干净整齐，总是支持培训过的TPM工作Implementandsustain5S贯彻并支持5SAnenvironmentthatissafe安全的环境Asurroundingthathelpsefficientworking有助于高效工作的环境“Visualworkplace”thathelpsavoidmistakesandhelpstrainnewemployeeseasily有助于避免发生错误、协助培训新员工工作的顺利进行的“可视的工作场所”Promoteasenseofownershipandprideintheworkplace在工作场所鼓励主人翁责任感和自豪感VisualWorkplaceVisualWorkplaceisaworkplacewhereproactivedisplayofallthenecessaryinformationthathelpsavoidmistakesandprovidesstatusataglance可视的工作场所可以预先展示全部必要信息，这有助于避免发生错误，并且看一眼就知道现场的状态Typicalinformationdisplayedvisually视觉上展示的典型信息Businessgoals,values,“dosanddon’ts”工作目标、价值观、应该做的和不应该做的Real-timeproductiontargetsandactualproduction实事的生产目标和实际产量Workinstructions,schedulesandassignments工作指示、时间进度表和分配Boundariesandindicationsoflocations工作场所的界限和标志Qualityresultsandtrends质量结果和趋势Specialprojects/teamsmessages,goals,achievements,etc.特殊的项目/团队信息、目标、取得的成绩等VisualsforTPMTPMTeam’sstoryboardTPM团队的描述板Alltheinfoontheproject,plans,achievedresults,etc.关于项目的全部信息、计划、取得的成绩等TPMStandards,schedules,assignmentsandreal-timestatusupdateTPM标准、时间进度表、工作分配和实时状态更新Instructionsforsafeoperationsandwarnings安全操作说明和警告Instructionsforinspectionandlubricationactivities检查和润滑工作说明Locationmarkingsofeveryneedediteminthearea区域内每项必需项目的位置标识Markingstohighlightnormalandabnormalconditions非常正常和