TPM方法培训资料课件

TPMMETHOD第一页，共三十九页。TPMGLOBALINDICATOR:THETRSTRS=QualityproductiontimeOpeningtimeTRS=NumberofgoodpartsproducedxCycletimeOpeningtime

Cycletime=Initialreference+improvementsInitialref.=Minimumtechnicaltime

第二页，共三十九页。TPMRELIABILITYINDICATORAverageofgoodworkingtimeMTBF=ActualproductiontimeNumberofrealstoppages

第三页，共三十九页。TPMRELIABILITYINDICATOR=MTBF(meantimebetweenfailure)Itistheaveragedurationinminutesduringwhichthemachineortheinstallationfunctionedwithoutanystoppages.Thestoppagesare:-machinebreakdowns-breakdownsrelatedtotools-breakdownsrelatedtotheproduct-stoppagesforchange-overs(usedorbroken)-stoppagesforfrequentadjustments-stoppagesforinspection(SPCsampling)-stoppagesformaintenance

Stoppagesfortoolchange-oversarenottakenintoaccount

第四页，共三十九页。TPMBREAKDOWNSANDMICRO-STOPPAGES:BREAKDOWNSStoppages>=5minsNotoftenSystematicallynotedStoppageaffectstheentireworkinggroupInterventionofanexpertResearchnecessarybeforestart-upIdentifiablecausesMICRO-STOPPAGESStoppages<5minsOftenNotnotedLittleornoperceptionbythegroupEasystart-upwithouteliminationofthecause(suppressionoftheeffect)NonidentifiedcausesLittlemotivationtoeliminatethembecauselittleperceivedimpactonproductionStronglyinvolvetheoperatorsandautomaticinstallationpeoplefortaskswithoutAddedValue第五页，共三十九页。TPMDATACOLLECTIONSBREAKDOWNRECORDSOFTHELAST6MONTHSPRODUCTIONNOTEBOOKSOPERATOREXPERIENCETHEDATEOFTHELASTTECHNICALMODIFICATIONDONEONONEPARTOFTHEMACHINE第六页，共三十九页。Paretoofunsolvedbreakdownsofthelast12monthsEliminatefromthisdatabasethesolvedbreakdownsPriorityistosolvebreakdownsthatrepresentthehigheststoppagesRepetitivebreakdownsmustbehighlightedbreakdown1breakdown2breakdown3breakdown4breakdown5breakdown6TPM:BreakdownsParetoanalysisofbreakdowns第七页，共三十九页。TPM:BREAKDOWNSTREATMENTMETHODOLOGYRegistertheanomalies(includingthebreakdowns)CarryouttherepairsDefinetheactionstoavoidrecurrenceConfirmthecauseSteering:SupervisorExecution:MaintenanceProf./WorkshopTechnicianMethod:ManagementofoperationsandsparepartsSteering:SupervisorExecution:MaintenanceProf.+TA+SupervisorMethod:1h30meetingonceaweek,5WhyoreventualcreationofaPSGSteering:SupervisorExecution:OperatorsMethod:RecordonanotebooknearthemachineorinstallationastheyoccurPROCESSPeopleConcernedMethodsKnowthehistoryofbreakdownsandcurrentwork

Tpsinterv. Resp.0to5mins: GAP5to15mins:Tech>15mins: Expert>30mins: Maintenance2134第八页，共三十九页。TPM:BREAKDOWNSTREATMENTMETHODOLOGYCreateormodifyifnecessarytheroutinesheetofpreventivemaintenanceApplythenewstandardSteering:SupervisorExecution:MaintenanceProf.+SupervisorMethod:Updateandvalidationofroutinesheet.Steering:SupervisorExecution:Operators+MaintenanceProf.Method:Followingthelevelofmaintenance,definethetrainingneedsandtrainthecontributorsSteering:AnimationtoreachobjectivesExecution:Applicationofformalisedinstructions56Thehistoryofbreakdownsistheback-updocumentoftheprocess,itisfoundonthemachineandisavailableforeverybody.Itiscompletedbythepersoncarryingoutthegiventask第九页，共三十九页。TPM:BREAKDOWNSWEEKLYMEETINGSUBJECT:breakdownsencounteredduringtheweek

PARTICIPANTS:supervisorandmaintenancetechnician

GOAL:ensurethatthedefinitivemeasureshavebeenimplementedtoavoidanyrecurrenceofbreakdowns

PLAN:weeklybreakdowninventoryforthepastweekexaminecausesactionstobeimplemented第十页，共三十九页。TPMMICRO-STOPPAGES:CHARACTERISATIONShut-down<5mnOftenNorecordsLittleornoperceptionbythegroupEasystart-upwithouteliminationofthecause(suppressionoftheeffect)UnidentifiedcauseLittlemotivationtoeliminatethembecauselittleperceivedimpactonproductionStronglyinvolvestheoperatorsandautomaticinstallationpeoplefortaskswithoutAddedValue第十一页，共三十九页。TPM:MICROSTOPPAGESTREATMENTMETHODOLOGYFromthenotedeffect,definethediagnosismethodofcausesRegisterthemicro-stoppagesSelectthemicro-stoppagetobetreatedQuantifythecauses(counting)Identifythepossiblecausesofthemicro-stoppagePROCESSPeopleConcernedMethodsSteering:SupervisorExecution:Operators,Supervisor,MaintenanceandManufacturingEngineeringTechniciansMethod:meetingsontheshopfloorwithproblemsolvingtools(Pareto-BrainStorming-5Mcause-effectdiagram-5Why's)Steering:SupervisorExecution:TechniciansandOperatorsMethod:Useofexhaustivefilmofallthemachineanomalies(withfollow-upofhumanintervention).ParetoSteering:SupervisorExecution:OperatorsMethod:Notedonnumberedworkstationform(counting)Steering:SupervisorExecution:MaintenanceExpertMethod:Formaliseandtraintheoperatorindiagnosis21354Selectthemachines第十二页，共三十九页。TPM:MICROSTOPPAGESTREATMENTMETHODOLOGYCreateormodifyifnecessarytheroutinesheetofpreventivemaintenanceSelectthecausestobetreatedinprioritySet-upthesolutionsLookforsolutionsContinuewiththe"counting"ofcausesofthemicro-stoppageSteering:SupervisorExecution:ManufacturingEngineeringTechnician-MaintenanceProf.-OperatorsMethod:Dependingonthelevelofmachinemodificationand/orlevelofmaintenanceDefinethetrainingneedsandtrainthecontributorsSteering:SupervisorExecution:PSGmembersMethod:Pareto-Balancing-BrainstormingSteering:SupervisorExecution:OperatorsMethod:Notedonworkstationform(counting)Applythenewstandard97610811第十三页，共三十九页。TPMROLEOFTHEOPERATORPREVENTIVEMAINTENANCECarryoutproductionoperationscorrectlyandsetupthemachineDoinspectionofthemachineeverydayMaintaintheperformanceofthemachineCleaning,Greasing,TighteningApplytheselfmaintenanceroutinesheetsCommunicatewithmaintenancedepartmentCarryoutthe"counting"ofmicro-stoppageregistrationsheetsCarryouttherecordingofmicro-stoppagescausesParticipatewithengineeringandtrialofnewequipment第十四页，共三十九页。TPMROLEOFTHEOPERATORCURATIVEMAINTENANCEPreparethemachineconditionsforrepair

Givetheirfeelingsaboutthemachineandtheiropinionsabouttheworkingconditions

Assisttechniciansduringrepairandheavymaintenance

ParticipateinPSGtoidentifysolutionsformicro-stoppageandbreakdown第十五页，共三十九页。TPM:MICRO-STOPPAGESOPERATORTRAININGStepsduringwhichtheoperatorbecomestrainedElaborationofcause-effectdiagram

Diagnosisofthecausesofmicro-stoppagesResearchforsolutionsCreationormodificationofthepreventivemaintenanceroutinesheetAcquiredknowledge

Constructionofacause-effectdiagram,methodologyandresearchofcauses,knowledgeoffactorsresponsibleforthecorrectfunctioningofthemachineDiagnosismethodologyofamalfunctionTechnicalknowledgeKnowledgeofmachinemaintenanceneeds

第十六页，共三十九页。TPMPREVENTIVEMAINTENANCETrainandassisttheoperatorsImprovethereliabilityofthemachineandstandardiseidenticalequipmentcapability,featurescycletimeImprovemaintainabilityDotechnicalinspectionthatneedexpertiseContinuousimprovementofmaintenanceorganizationParticipateintheengineeringofnewequipmentROLEOFTHEMAINTENANCEDEPARTMENT第十七页，共三十九页。TPMExamplesofvisualmeansPositionmarkings(machines,tooling,tools,products,etc.)Colourcodingbyfunction,productorworkshopLightpaintondirtyobjectsCupboardswithoutdoorsEtc...VISUALORGANISATION第十八页，共三十九页。ExperienceanalysisTPM:preventivemaintenance

JanvierFévrierMarsAvrilMaiJuinJuilletSeptembreOctobreNovembreDécembreVidangemoteur

Vérificationserragevissupportbâti

Graissagecarter

Contrôletensionetusurecourroie

Contrôledimensionnelaxe

MachineAtelierConfigurationinitialeDate:EnsembleNote:NouvelleconfigurationBoardforschedulingthepreventivemaintenancePreventivemaintenanceprocedureReportoftheinspectionanomaliesHistoricalaccount123345Weeklymeetings

PropertyofValeo-Duplicationprohibited第十九页，共三十九页。

JanvierFévrierMarsAvrilMaiJuinJuilletSeptembreOctobreNovembreDécembreVidangemoteur

Vérificationserragevissupportbâti

Graissagecarter

Contrôletensionetusurecourroie

Contrôledimensionnelaxe

BoardordatasheetforschedulingthepreventivemaintenanceTobedoneJLObserveddefectfinishedJLNothingwrongTPM:preventivemaintenanceWorkingconditionsPropertyofValeo-Duplicationprohibited第二十页，共三十九页。EXAMPLESObviousTPMVisualmarkforMinandMaxlevelsMarktolocatethestoppositionofamobilepartofamachineRedmarkforpressuremanometerImportantscrewswithnuttighteningarerepairedwithvisualmark(see2onpage49)Greaselocationsarehighlightedwitharrows,numberedandcolouredPartlistislabelledoncontainers(oiltank,pumpforgreasingoperations...)第二十一页，共三十九页。

EXAMPLESObviousTPM123第二十二页，共三十九页。FIELDAPPLICATION第二十三页，共三十九页。TPMPILOTWORKSHOPCRITERIA

Lineorbottle-neckmachines(inordertogaincapacityandavailability)Presentingalow"MTBF"StronglypenalisingtheflowSemi-automaticinstallationsconsistingofmanualworkstations(theactivityoftheoperatordependsuponthegoodfunctioningoftheinstallation)第二十四页，共三十九页。schedulesPreliminary"5S"operationsimplementationofcleaningprocedureimplementationofinspectionprocedurevisualorganisationTPMmethodologyTRSmeasureMTBFmeasureTreatmentofbreakdownsTreatmentofmicro-stoppagesComplementthepreventivemaintenanceprocedureTPM第二十五页，共三十九页。TPM:MICROSTOPPAGESTREATMENTMETHODOLOGYFromthenotedeffect,definethediagnosismethodofcausesRecordthemicro-stoppagesSelectthemicro-stoppagetobetreatedQuantifythecauses(counting)Identifythepossiblecausesofthemicro-stoppagePROCESSPeopleConcernedMethodsSteering:SupervisorExecution:Operators,Supervisor,MaintenanceandManufacturingEngineeringTechniciansMethods:meetingsontheshopfloorwithproblemsolvingtools(Pareto-BrainStorming-5Mcause-effectdiagram-5Why's)Steering:SupervisorExecution:TechniciansandOperatorsMethods:Useofexhaustivefilmofallthemachineanomalies(withfollow-upofhumanintervention).ParetoSteering:SupervisorExecution:OperatorsMethods:Notedonnumberedworkstationform(counting)Steering:SupervisorExecution:MaintenanceExpertMethods:Formaliseandtraintheoperatorindiagnosis21354Selectthemachines第二十六页，共三十九页。TPM:MICROSTOPPAGESTREATMENTMETHODOLOGYCreateormodifyifnecessarythepreventivemaintenanceroutinesheetSelectthecausestotreatinprioritySet-upthesolutionsLookforsolutionsContinuethe"counting"ofthecausesofthemicro-stoppageSteering:Maintenance,ManufacturingEngineeringExecution:ManufacturingEngineeringTechnician-MaintenanceProf.-OperatorsMethod:Dependingonlevelofmachinemodificationand/orlevelofmaintenanceDefinethetrainingneedsandtrainthecontributorsSteering:PSGLeaderExecution:PSGteammembersMethod:Pareto-Balancing-BrainstormingSteering:SupervisorExecution:OperatorsMethod:Registeredonworkstationsheet(counting)Applythenewstandard97610811Lookforsolutions第二十七页，共三十九页。TPMWORKSHOPSRESULTS第二十八页，共三十九页。FEEDBACKTODESIGN第二十九页，共三十九页。specificationbooksetup/startofthemachineUp'datingofpreventiveroutinedatasheetCollectionofexperienceBuildingofpreventivemaintenancebookletFMECA5"S"TPMSupplieradvicesbreakdownMicro-stoppagesQualitySafetyPREVENTIVEMAINTENANCEELABORATION第三十页，共三十九页。FMECATPM:FMECAFailureModesandEffectsCriticalityAnalysis

TooltoimproveunderstandingoftheworkingconditionsandthestoprisksofamachineIdentifytheweakpartsofamachineStudyeffectsoffailure(ReliabilityMaintainabilityRiskSafety)StudyandplansolutionsforcorrectiveandpreventiveactionstoimprovereliabilityRulestooperatethemachinetoitsoptimum第三十一页，共三十九页。TPM:FMECAThinkingapproachCAUSE:Whydiditoccur?

EFFECT:Whathashappenedaccordingtothemachineoperator?Themachineitself?第三十二页，共三十九页。TPM:FMECAQuotationGravityvalueMinorMidleCriticaldisastrousRepairtime

<5minRepairtimebetween5&15mn

Repairtimebetween15&60mnRepairtime>60mnorquality/saafetyriskFrequencyvalueAnnualquarterlyweeklydailyLess1fault/yearrMax1fault/quaterMax1fault/week1fault/dayDetectionprobabilityMinorMiddleCriticaldisastrousDetectionprobabilityPrevioussignsbeforefailureleadingtopreventivemaintenancePreviousindicationsbutnonenoticeablefortheoperatorNoPrevioussignbeforefailurePrevioussignsbeforefailurebutdifficulttoseebytheoperator第三十三页，共三十九页。CorrectivesactionsTPM:FMECARiskpriorityindex IPR=GxFxD11664IPRcausesnumbercorrectivesactionsnecessary第三十四页，共三十九页。THEMAINTENANCE