AM training material 自主维护培训教材

Autonomous&ProfessionalMaintenance自主/专业保养

IntroductiontoPractitionercourse–Module1

实践课程的介绍—模块1SafetyComesFirst!安全第一BecauseitissoImportant!安全重于一切BuildingacultureofresponsibilityandCARE!建立负责及关心的氛围NOmobilesorlaptopsallowedastheydisrupt不允带手机电脑Putonsilent!保持肃静Useonly

duringbreaks!课间才可用RespecttheWorkshop尊重课堂纪律确保理解所学内容Ensureyouunderstand

thepointsonthe

agendaorpresentationIFNOT,

ASK!否则提问RespectYourself尊重自己Respectthetimewehave尊重我们付出的时间Starttimes!开始时间Learningtime学习时间Funtime休息时间WorkshopGroundrules课程基本规定ProgrammeContent活动内容MondayTuesdayWednesdayThursdayFridaySaturdayPMPMPMAMAMAM

TOBEUPDATED更新ProgrammeContent活动内容OLDFORMAT表格Monday14thSeptTuesday15thSeptWednesday16thSeptThursday17thSeptFriday18thSeptOpeningIntroductions介绍LearningReview复习LearningReview复习LearningReview复习LearningReview复习IntroductiontoTPM介绍TPMIntroductiontoAM介绍AM

Step1Introduction步骤1介绍Step2Introduction步骤2介绍Step3Introduction步骤3介绍StepAuditing审核步骤AMStep0Preparation准备Step1Practicalbriefing&Teampreparation步骤1实操报告和团队准备Step2Practicalbriefing&Teampreparation步骤2实操报告和团队准备Step3Practicalbriefing&Teampreparation步骤3实操报告和团队准备StepAuditingPracticalbriefing&preparation审核步骤实操包噶和预备

AMStep0TeamPracticalPreparation步骤0实操预备

AMStep1Practical自主维护步骤1实操AMStep2Practical自主维护步骤2实操AMStep3

Practical自主维护步骤3实操DetailedPillarandStepAudit详细的模块和审核步骤Lunch

AMStep0Practical

(Machineintermittentminorstoptime–notouch!)自护维护步骤0实操（设备间断的小故障-不管）

Step1PracticalContinued步骤1实操持续Step2PracticalContinued步骤2实操持续Step3PracticalContinued步骤3实操持续

+RefinementofSteps0-2步骤0-2的改进

100-DayDetailedPilotPlanning100天详细的改善计划

ReviewandClose回顾和关闭

TeamPresentations团队报告TeamPresentations团队报告TeamPresentations团队报告TeamPresentations团队报告

ReviewandClose回顾和关闭ReviewandClose回顾和关闭ReviewandClose回顾和关闭ReviewandClose回顾和关闭

EvenDustAmassedwillgrowintoaMountain积沙成塔

ThoughtfortheWorkshop想下我们的车间Autonomous&ProfessionalMaintenance自主维护&专业维护

IntroductiontoTPM全员生产维护介绍Version2-February2014SAF–Safety安全1CD–CostDeployment成本部署FI–FocusedImprovement集中改进WO–WorkplaceOrganization工作场所优化AM–AutonomousMaintenance自主维护PM–ProfessionalMaintenance专业维护Q&PC–Quality&ProcessControl质量&过程控制LOG–Logistics&Customerservice物流&客户服务EEM–EarlyEquipmentManagement早期设备管理EPM–EarlyProductManagement早期产品管理PD–PeopleDevelopment人员发展ENV–Environment环境保护23456789101112WAMProgramWAM程序SAF–Safety安全1CD–CostDeployment成本部署FI–FocusedImprovement集中改进WO–WorkplaceOrganization工作场所优化AM–AutonomousMaintenance自主维护PM–ProfessionalMaintenance专业维护Q&PC–Quality&ProcessControl质量&过程控制LOG–Logistics&Customerservice物流&客户服务EEM–EarlyEquipmentManagement早期设备管理EPM–EarlyProductManagement早期产品管理PD–PeopleDevelopment人员发展ENV–Environment环境保护23456789101112TPMTheTPMmodelTPM模块TOTAL全部的TheinvolvementandengagementoftheEVERYONEintheworkforcefromthePlantManagertothefrontlineemployees.

从厂长到一线员工的所有人员的参与及承诺PRODUCTIVE生产的Thedevelopmentofaproductiveculturethatcontinuallyseekstoimprovefactoryperformance.

持续寻求提升工厂绩效的生产环境的改善MAINTENANCE维修，维护，保养Tomaintainorsustaintheconditionsandstandardsachievedfromimprovementornew

维持或维护已改进的或新设置的条件及标准TPMReminderofwhatTPMis!TPM概念提示AM–AutonomousMaintenance自主维护PM–ProfessionalMaintenance专业维护56Thebackboneoftheapplicationoffocused

TPMisAM/PMSynergy

集中进行全员生产维护的支柱是AM/PM协作AM/PMSynergy自主维护/专业维护协作ENGAGINGTHEMASSINTHEPROGRAMME激励系统中的所有人AM/PMSynergy自主维护/专业维护协作MaximisethePlantavailabilityatthelowesteconomicalcost

最大化工厂资源的利用AchieveandSustainZeroBreakdowns

达到并维持0停机的目标保持沉默——等待停机停机AssetCareistheprogrammethatcombinestheeffortsofMaintenancethroughPMandOperatorsthroughAM

资产维护计划包括维修的专业维护以及生产员工的自主维护Performance绩效Time时间OEETargetImprove改进5SAM–AutonomousMaintenancePM–ProfessionalMaintenanceAM/PMSynergy自主维护/专业维护协作Sustain维持Phase1-Initialfocusistostopfailures&

establishbasicconditioncontrolthrough

restorationofthemachineconditions

阶段1-初始阶段致力于停止故障&通过恢复设备条件

以建立基本条件控制Performance执行Time时间OEETimeDeterioration老化..Forced/AcceleratedDeterioration被迫和加速老化NaturalDeterioration自然老化FAILUREFailuretoMaintainBasicConditions维护失败1FailuretoObserve检查失败OperatingConditions2FailuretoRestoreEquipment设备复原失败3DesignWeakness设计薄弱4InsufficientOperatoror人手不足Insufficient技能不足MaintenanceSkills5AM–AutonomousMaintenancePM–ProfessionalMaintenanceAM/PMSynergy自主维护/专业维护协作ForcedDeterioration强制恶化Humanerrorordeliberateaction

人为失误或有计划的行动

AcceleratedDeterioration

加速恶化

Insufficientlubricant,

contamination,

poortightening

oradjustment

不足的润滑，

污染

不良的紧固或调整

AM/PMSynergy自主维护/专业维护协作UnderstandingDeterioration了解恶化

NaturalDeterioration自然恶化ThenormallifeexpectancywithNOadverseinfluence

没有负面影响的正常使用寿命WhyClean?为什么清扫1DUSTDAMAGESMACHINESCREATINGFORCEDDETERIORATION灰尘会产生强制恶化，从而损坏机器AM/PMSynergy自主维护/专业维护协作UnderstandingtheBasicConditions

了解基本条件RestorationCleaningTighteningLubricatingAM/PMSynergy自主维护/专业维护协作UnderstandingtheBasicConditions了解基本条件Clean

清扫Tight

紧固Lubricated

润滑Understandingtheneedfor

inspection了解检查的需求REVEALTHEHIDDENDEFECTS发现隐藏的缺陷Splits,cracks,Worn&missingparts!2AM/PMSynergy自主维护/专业维护协作UnderstandingtheBasicConditions

了解基本条件DetailedcleaningtoremoveALLcontaminationensuresthatALLpartsoftheequipmentaretouched.OnlyinthiswaycanwefindtheseHiddenDefects.彻底的清扫以消除所有污染，保证可以接触到设备的任何部分，只有这种方法可以找到这些隐藏的缺陷WhyClean?为什么清扫AM/PMSynergy自主维护/专业维护协作UnderstandingtheBasicConditions

了解基本条件Tightening紧固Asimplebutcriticaltask!一个简单但是关键的工作Sometoolsare

justforgripping!某些工具只有夹紧功能Whichistherighttoolforthejob?

哪个才是合适的工具？AM/PMSynergy自主维护/专业维护协作UnderstandingtheBasicConditions

了解基本条件Tightening:isitreallythatsimple?

紧固：有没有准备好方便取用Wheredidthesecomefrom?这是从哪里来的？Howtightistight?

如何才算是紧固的AM/PMSynergy自主维护/专业维护协作UnderstandingtheBasicConditions

了解基本条件Tightening:MaybeitisNOT!

紧固：或许它没有紧固！MissingBolt!Isitreallyneeded?缺失的螺丝！它真的需要吗？UnderLubricated!正常润滑OverLubricated!过度润滑WhatHappened?发生了什么AM/PMSynergy自主维护/专业维护协作UnderstandingtheBasicConditions

了解基本条件Lubricated润滑AM/PMSynergy自主维护/专业维护协作UnderstandingDeterioration了解恶化

Doesthisreallymatter?这真的是问题吗？FailureContamination污染Over

tightening太紧Loosenuts

andbolts松的螺丝Under

lubrication没油Over

Lubrication油多Wornparts磨损零件DefectiveParts缺陷零件wrongparts错零件Missing

parts遗失零件Vibration震动Under

tightening太松BASICCONDITIONS基本情况AM/PMSynergy自主维护/专业维护协作UnderstandingDeteriorationand BasicConditioncontrol了解恶化及基本条件WHYDOWEINSPECT?为什么检查

TocheckforKNOWNdefects检查已知的缺陷Regularinspectionoftheseknownareas,candetectdeviationsandberectifiedbeforeanyeffectisregistered.对已知区域的常规检查，可以检测到偏离，并在发生任何不良后果前做出调整KnowntohaveConnectionsthatsplit知道接头断开Greaseknowntoleakfrompiston从活塞回到缺油Wearknownonroller轴承磨损AM/PMSynergy自主维护/专业维护协作CHANGEPEOPLE<>CHANGEMACHINE

人员变化机器变化StabiliseEquipmentconditions固化设备条件StopAcceleratedDeterioration停止加速恶化PreciselyJudgeNormalfromAbnormalconditions正确的从异常条件中判断正常TakeQuickandProperActionstoCorrectAbnormalities进行快速恰当的处理来纠正变异SticktotheRules(ConditionControl)遵守规定（控制条件）OperatorCompetencyDevelopment操作人员能力的发展AM/PMSynergy自主维护/专业维护协作CHANGEPEOPLE<>CHANGEMACHINE

人员变化机器变化MakeitEASYtodothe使第一次以及每次做正确的事情变得简单

RightthingsFirsttimeEverytimeAM/PMSynergy自主维护/专业维护协作CHANGEPEOPLE<>CHANGEMACHINE换人<>换设备

AM/PMSynergy自主维护/专业维护协作AM/PM:howtostart?如何开始Youcan’tsolveallissuesatthesametime!我们无法一次性解决所有问题Equipmentclassification%distributionStartfromthecriticalones!从关键部分开始MODELAREAAPPROACH示范区Youcan’tsolveallissuesatthesametime!我们无法一次性解决所有问题AM/PM:howtostart?如何开始Phase1:StepbyStepProjectApproach阶段1：一步一步的达成项目AMStep1Step3Step2Step0Step1Step3Step2PMAM/PM:thejourney旅程Initialcleaning最初清洁TentativeStandards试验性的标准Countermeasuresagainstsources针对根源的对策Education:MachineSafetyandfunction学习：设备安全和功用Step1步骤1Eliminationofforceddeteriorationandpreventionofaccelerateddeterioration根除被动恶化和预防加速恶化Step3步骤3EstablishmentofmaintenanceStandards建立维修标准Step2步骤2Reversedeterioration(breakdownanalysis)逆转恶化（停机分析）Phase2:astheprogrammemovesonintoPhase2andextendinglife,thentheAMprogrammeevolvesaswell阶段2：当系统进行到阶段2并拓展到所有区域及设备的整个使用寿命，AM系统则达到良好的状态PerformanceTimeOEETargetImproveSustain5SAM–AutonomousMaintenancePM–ProfessionalMaintenanceAM/PM:thejourney旅程AutonomousMaintenance自主维护

Basics基础知识Version2–February2014WAMProgramSAF–安全生产1CD–成本控制FI–持续改善WO–工作现场优化AM–维护保养PM–紧急维修Q&PC–质量和工艺控制LOG–物流客服EEM–设备设计EPM–配方设计PD–人员发展ENV–环境保护23456789101112OBJECTIVES目标ZeroBreakdownsduetolackofbasicconditions因缺少基本条件而造成的停机,目标为零Maximizeeffectivenessbyeliminationofresiduallosses通过消除剩余损失达到效率最大化AM–AutonomousMaintenance自主维护VISION愿景Operatorseliminatelossesthroughmaintenanceactivities员工通过自主维护活动来消除损失AMVision&Objectives

AM愿景和目标Breakdownsduetolackofbasicconditions[n°]缺少基本条件而造成的停机次数[次数]Cleaning,InspectionandLubricationtimes[min/week]清洁,检查和润滑次数[分钟/每周]OEE(OverallEquipmentEffectiveness)[%]设备综合效率[%]Benefit/CostratioofAMprojects自主维护项目的效益/成本比率Tagsissued/solved[n°]红牌发放和解决[个数]PeopleinvolvedintoAMprojects[n°]参与AM项目的人员[人数]OPL,SOPissued[n°]单点教材,标准作业操作程序的发行[个数]KPI重要绩效指标KAI重要活动指标KPI&KAI关键考核指标和关键活动指标MachineImprovementProjectActivity设备提高项目活动AMStep1Step3Step2Step0AMStep0自主维护步骤0Education:MachineSafetyandfunctionInstillanunderstandingofhowForcedDeteriorationoccursandwhyAMisnecessarynowEnsurethatSafetyisparamountinAMActivitiesDevelopanunderstandingofHowtheMachineWorksfortheParticipantsintheAMprogramme培训:机器的安全性和功能灌输理解机器被迫恶化是如何发生的,和为什么自主维护是必须的确保安全在自主维护活动中是首要的深入了解在自主维护计划中,机器是怎样为参与则工作Initialcleaning最初清洁TentativeStandards试验性的标准Countermeasuresagainstsources针对根源的对策Education:MachineSafetyandfunction学习：设备安全和功用MachineImprovementProjectActivity设备提高项目活动AMStep1InitialcleaningStep3TentativestandardsStep2CountermeasuresagainstsourcesStep0Education:MachineSafetyandfunctionAMStep1步骤1InitialCleaning&InspectionCompletelyremovealltracesofcontaminationfromallpartsoftheequipmentRevealandtaghiddendefectsIdentifyandtagsourcesofcontamination(Dust!!)IdentifyandtaghardtoaccessareasRemovalofunnecessaryitems,andcreateorderlinessandtidiness初始清洁和检查彻底地将设备上所有部件的污染痕迹去除暴露并标识隐蔽的缺陷识别并标识(灰尘)污染源识别并标识难以接近的区域移去不必要的物品,创建整齐和整洁的工作环境AMStep1InitialcleaningStep3TentativestandardsStep2CountermeasuresagainstsourcesStep0Education:MachineSafetyandfunctionAMStep2Counter-measurestoEliminateSourcesofContaminationandHardtoAccessareasEliminatethesourcesofcontaminationEliminatethe"inaccessible"areasReducetimetocleanandinspectequipmentDevelopinitialstandardsforcleaning,tighteningandinspectionDevelopeffectiveproblemsolvingapproache.g.QuickKaizenand5whysanalysistechniques消除污染源和难以接近区域的措施消除污染源消除难以接近的区域减少清洁和检查设备的时间建立清洁,紧固和检查的初始标准发展建立解决问题的有效方法,例如:快速改善和5WHYS分析方法MachineImprovementProjectActivity设备提高项目活动AMStep1InitialcleaningStep3TentativestandardsStep2CountermeasuresagainstsourcesStep0Education:MachineSafetyandfunctionAMStep3步骤3DevelopTentativeCILRStandardsLubricationsystemisfullyreviewedandoptimized“Engineering”traintheoperatorsinlubricationOperatorssettheLubricationStandardsfortheEquipmentcombinedwiththeStep2CleaningStandardsTheMaintenanceCalendarincludestheCILRstandardsandarestandardoperatingpractice.Thereisaneffectivelubricationenvironmentestablished建立暂时的CILR标准全面地审查和优化润滑系统设备工程师对员工进行专业的润滑培训员工结合步骤2的清洁标准建立设备的润滑标准维护日程应包括CILR标准和操作实践标准要建立一个有效的润滑环境MachineImprovementProjectActivity设备提高项目活动AMNextsteps自主维护下一步MachineImprovementProjectActivity设备提高项目活动首次清洁针对污染源和难检修的措施暂行标准综合设备检查综合工作区域检查个人区域管理全面提升自动化管理AutonomousMaintenance

Step0

Education:MachineSafety,Function&Condition培训:机器安全,功能及基本状况Version2–February2014AMStep0自主维护步骤0StepbyStepProjectApproach一步步的项目路径AMStep1Initialcleaning首次清洁Step3TentativeStandards暂行标准Step2Countermeasuresagainstsources污染源措施Step0Education:MachineSafetyandfunction培训：设备安全和功能Step1Eliminationofforceddeteriorationandpreventionofaccelerateddeterioration非正常的老化消除和加速老化的预防Step3EstablishmentofmaintenanceStandards维护标准建立Step2Reversedeterioration(breakdownanalysis)扭转退化（停机分析）PMAMStep0AMStep1Step3Step2Step0AMStep0Education:MachineSafetyandfunctionInstillanunderstandingofhowForcedDeteriorationoccursandwhyAMisnecessarynowEnsurethatSafetyisparamountinAMActivitiesDevelopanunderstandingofHowtheMachineWorksfortheParticipantsintheAMprogramme培训:机器的安全性和功能灌输理解机器被迫恶化是如何发生的,和为什么自主维护是必须的确保安全在自主维护活动中是首要的深入了解在自主维护计划中,机器是怎样为参与则工作Initialcleaning首次清洁TentativeStandards暂行标准Countermeasuresagainstsources污染源措施Education:MachineSafetyandfunction培训：设备安全和功能WHATAREYOUGOINGTOACHIEVE?达到什么目的SettheVision&Objectives设定愿景和目标Settheteam建立团队TraintheteamonAMtools培训团队有关AM的工具WHERESHOULDYOUFOCUS&WHY?关注点及原因StratificationofLosses损失的分类Datacollectiononbreakdownsofthemachine收集机器故障的数据HOWAREYOUGOINGTOGETTHERE?怎样达到目标FormalizingtheProject形成一个项目DevelopingthePlan制定计划AMStep0–preparation准备WHATAREYOUGOINGTOACHIEVE?你的目的是什么SettheVision&Objectives建立远景和目标Example: ToachieveZeroaccidents,Zerobreakdowns,Zerominor stoppages,Zeroqualitydefectsonthemachine例如:取得机器零事故,零故障,零小停机,零质量缺陷Example: Zerobreakdownsduetolackofbasicconditions(actual6permonth) Zerobreakdownsduetohumanerrors(actual2permonth) Zeroaccidents例如:由于缺乏基本条件而造成的停机,目标为零(实际是每月6次)

人为失误而造成的停机,目标为零(实际是每月2次)

零安全事故AMStep0–preparation准备WHATAREYOUGOINGTOACHIEVE?目的是什么Settheteam建立团队AMStep0–preparation准备WHATAREYOUGOINGTOACHIEVE?目的是什么TraintheteamonAMtools培训团队自主维护工具PrepareOPL’stoexplaintotheteamwhatAutonomousMaintenanceis…准备一点通向团队说明自主维护是什么AMStep0–preparation准备WHATAREYOUGOINGTOACHIEVE?目的是什么TraintheteamonAMtools培训团队自主维护工具…andusetheTRAININGMATRIXtotrackanddrivethedevelopmentofyourteam!…使用矩阵表跟踪人员技能培训,推进团队的进展XXXXXXXXXXXTeammember1XTeammember2Teammember3Teammember4Teammember5Teammember6OPL/SOPAccelerateddeteriorat.EquipClassifiicationRiskAssessmentLockout/TagoutTaggingXXXSuccesssheetXXXXXQuickkaizenXXXXXXXXXXXXXXXXXXAMStep0–preparation准备WHERESHOULDYOUFOCUS&WHY?关注的地方和原因StratificationofLosses损失分类Reviewof检查:

LossandCostDeployments

损失成本部署PMPrioritisationClassification

专业维护的分类和优先次序BreakdownReports

故障报告BasicConditionsonthemachine

机器基本状况的回顾AMStep0–preparation准备HOWAREYOUGOINGTOGETTHERE?你计划怎样达到目标FormalizingtheProject正式立项Formalizeteam,drivingkpi,targets,budgetandtiming建立团队,KPI,目标,预算和时间Defineallkpi’sandkai’stotrackduringtheproject定义KPI和KAI以便在项目实施过程中跟踪AMStep0–preparation准备HOWAREYOUGOINGTOGETTHERE?怎样达到目标DevelopingthePlan做计划Scheduletheactivitiestodoandtrackwhenyoureallyworkonthem列行动计划去做和跟踪你真的何时去完成他们Usedetailedactionplansasnecessary如有必要就要使用详细的行动计划AMStep0–preparation准备HOWITWORKS怎样工作？MachinefunctionandOperation机器功能和运作NormalvAbnormal正常状态和异常状态

HOWTOBESAFE怎样安全People:Machine:Product

人员:机器:产品COMMUNICATION&TRAINING沟通和培训UseofOPL’sandSkillsMatrix使用一点通和技能矩阵表AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGTHEMACHINE

ANDHOWITWORKS理解机器的工作原理MachinefunctionandOperation机器功能和运作NormalvAbnormal正常状态和异常状态

THEPROCESS步骤技术员一步一步地解释团队成员画图以便帮助理解团队成员深入一些有关机器正常和异常状态运作时的问题团队成员在技术员的帮助下,通过单点教材回答这些问题AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGTHEMACHINEANDHOWITWORKSUsingMechanismDrawings通过机械图纸帮助理解机器的工作原理

StepbystepexplanationofhowtheproductMovesthroughthesystem.一步一步地解释产品是怎样通过整个系统Severaldrawingsmaybeused,orevenmodels.需要用到一些图纸或者是模型AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGTHEMACHINEANDHOWITWORKSUsingMechanismDrawings通过机械图纸帮助理解机器的工作原理AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGTHEMACHINEANDHOWITWORKSUsingOnePointLessons使用一点通去理解设备和怎样工作原理

TheteammembersanswerthequestionsusingOPL’s.团队成员通过一点通的形式回答问题

Everyoneisencouragedtodothem!!鼓励每个人都参与其中

GoodOPL’s20%Words–80%PicturesTheyareuseful!!Trainedoutin5minutes.Nophotographs!好的单点教材是20%文字加80%图片AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGTHEMACHINEANDHOWITWORKSUsingOnePointLessons使用一点通去理解设备和怎样工作原理

3BasicTypesofOPLSAFETYBASICKNOWLEDGEIMPROVEMENTAMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGTHEMACHINEANDHOWITWORKSRemembertoChallenge–WhatisNormalvAbnormal记住这个挑战什么是正常和异常

Shouldtherebecapsonthegreasenipples?应该有油嘴帽吗？WhichIsNormal?哪个是正常IfIdon’tknowwhatisnormal,HowwillIfindabnormalities如果我不知道什么是正常，那我怎么知道异常？AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGHOWTOBESAFE理解怎样才是安全状态Foryou,themachineandtheproduct对你,机器和产品,安全在AM活动中是首要的.

ENSURESAFETYISPARAMOUNTINALLAMACTIVITIES确保安全是所有自主活动中个最重要的AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGHOWTOBESAFEApproach方法Foreachcleaningtask,assesstherisksto每个清洁工作都要评估以下的风险:PEOPLE人MACHINE设备PRODUCT产品Eliminateorreduceidentifiedrisksapplyingpreventativemeasures

通过预防措施消除或减少已识别的风险CommunicateoutusingOPLs通过一点通进行沟通AMStep0-machinefunctionandsafety设备功能和安全Allcleaningtaskshavetobelistedandevaluated!所有清洁任务都要被列入和评估AMStep0-machinefunctionandsafety设备功能和安全PROBABILITY概率PEOPLERiskmatrix人员风险评估矩阵SEVERITY严重性AMStep0-machinefunctionandsafety设备功能和安全MACHINERiskmatrix设备风险评估矩阵PROBABILITY概率SEVERITY严重性AMStep0-machinefunctionandsafety设备功能和安全PRODUCTRiskmatrix产品风险评估矩阵PROBABILITY概率SEVERITY严重性AMStep0-machinefunctionandsafety设备功能和安全AMStep0-machinefunctionandsafety设备功能和安全Countermeasure措施Cleaningrollers清洁轴承-XGloves手套Cuttingarm切手Sharpedges锋利边EI5210Coveringsharpedges包边1911NameDateXUNDERSTANDINGHOWTOBESAFE理解怎样更安全MachineIsolationFirstandForemost设备首先是断电

HighvisibilityofLOTO

procedureandstandards

LOTOSheetMachinelayout设备布局图Procedure过程AMStep0-machinefunctionandsafety设备功能和安全UNDERSTANDINGHOWTOBESAFE理解怎样更安全UsingaRiskMaptohighlightwheretherisksare通过风险图突出危险区域

Focusonhighriskareasofthemachine!关注机器的高危险部分Showrisktype危险类型…Recordrisklevel(BeforeandAfter)记录危险级别(以前和之后)AMStep0-machinefunctionandsafety设备功能和安全COMMUNICATION&TRAINING沟通和培训UseOPLsfordailytransferacrosstheshiftsofvalueaddedinformation通过一点通传递日常班组间的有价值信息AMStep0-communication&training沟通和培训OPERATOR操作员LearnsaboutwhatAMis,andwhyitisimportant.RelatedtoLossandOEELearnsaboutthemachine

andsafetyaspectsrelatedtocleaning.IdentifieshowAMactivitycanbesafeandputscontrolsinPlace.Raisesquestionsandanswers

them.Transferstheirlearningtootherteammembers.了解什么是自主维护自主维护的重要性

及有关损失和设备综合效率了解机器和清洁机器有关的安全方面

识别怎样才是安全的自主维护活动

并控制到位提出问题,并回答将自己学习的内容传给其他成员TECHNICIAN技工Identifiestherelevantequipmentforfocusandgathersthedatatosupport.Teachestheoperatoraboutthemachine,itsfunctionandoperation.Teachestheoperatoraboutwhatisnormalandwhatisabnormal.Understandsthemachineperformance,throughinitialanalysisandobservation.识别相关设备的关注点

收集数据来支持改善教会员工机器的功能和操作教会员工什么是机器的正常状态,什么是异常状态通过初步的分析和观察,理解机器的性能SUPERVISOR主管Understandsthemachineperformancedata.SetsupCommunicationsystemfortheteam.Establishesobjectivesforandwiththeteam.Establishesarealisticplanwiththeteambaseduponthemanagementpilotmodel.Ensuresacceptablesafetystandardsarebeingdevelopedandcompliedwith.Checksplanisadheredtoandinitiatesauditprotocol.Ensuresresourcesaremadeavailabletotheteam理解机器性能数据为团队建立交流平台

和团队一起建立团队的目标基于管理层选定的试验模型,和团队一起制定一个可实现的计划确保建立可接收的安全标准,并遵守执行坚持审核计划,并开始审计协议确保团队需要的资源AMStep0–responsibilities责任KEYPOINTS

Step0activityprovidesthenecessaryfoundationinordertogainrealvaluefromthenextimprovementsteps.

NorecognitionofHazards= Accidents!!

Nounderstandingofloss= Nomotivationtofindrealproblems

Nounderstandingof= ProblemswillNOTbefoundand

NormalvAbnormal theoperatorwillbecome

increasinglyfrustratedjustcleaning

Norelationshipwith= WrongKnowledge,damagingmachinesMaintenance/Technical machinesfurther.Wallsbeingbuiltwith uselesstags!!MaintenanceOperatorAMStep0要点KEYPOINTS

步骤0提供了一些必要的基础内容,为了下一步的改善获取真正有价值的东西

不承认危害=事故!!

不理解损失=没有动力去发现真正的问题

不理解正常和异常状态=就不能发现问题,员工仅是做清洁,会日渐感到受挫

与维修或技术没有关系

=错误的认识会毁坏机器,机器越是恶化,墙上就会挂牌越多AMStep0-Activityboard行动信息板AutonomousMaintenance自主维护

Step1步骤1

Initialcleaning最初清洁Version2–March2014AMStep1自主维护步骤1StepbyStepProjectApproach逐步项目达成AM自主维护Step1Initialcleaning最初清洁Step3TentativeStandards试验性的标准Step2Countermeasuresagainstsources针对根源的对策Step0Education:MachineSafetyandfunction学习：设备安全和功用Step1步骤1Eliminationofforceddeteriorationandpreventionofaccelerateddeterioration根除被动恶化和预防加速恶化Step3步骤3EstablishmentofmaintenanceStandards建立维修标准Step2步骤2Reversedeterioration(breakdownanalysis)逆转恶化（停机分析）PM专业维护AMStep1AM自主维护步骤1AMStep1InitialcleaningStep3TentativestandardsStep2CountermeasuresagainstsourcesStep0Education:MachineSafetyandfunctionAMStep1AM自主维护步骤1InitialCleaning&Inspection最初清洁和检查Completelyremovealltracesofcontaminationfromallpartsoftheequipment从设备的所有部件上面将所有的污迹消除Revealandtaghiddendefects挂牌标识出隐蔽的缺陷Identifyandtagsourcesofcontamination(Dust!!)对污迹的源头识别和挂牌（灰尘）Identifyandtaghardtoaccessareas难易接近的区域识别和挂牌Removalofunnecessaryitems,andcreateorderlinessandtidiness移走不需要的东西，营造整齐和整洁的现场FROMSTEP0WEKNOWWHYWECLEAN!从步骤0我们知道我们为什么要清洁！Completelyremovealltracesofcontaminationfromallpartsoftheequipment.从设备的所有部件上面将所有的污迹消除Topreventaccelerateddeteriorationcausedbycontaminationinthesystemandmechanisms.预防因系统和设备污物导致的加速恶化。Toensurethatallhiddendefectsareexposedandcaptured.确保所有隐性的缺陷都被暴露和解决

CLEANINGISINSPECTION清洁的过程在检查INSPECTIONISDETECTION检查的过程在发现!AMStep1AM自主维护步骤1Weneedtorevealandcapture,throughcleaning我们要通过清洁暴露和发现问题Sourcesofcontamination污染的源头Hardtoaccessarea难以接近的区域Abnormalities异常状况

Redundantparts

Toachievethiswemustensurethateverypartofthemachineistouched!要达到这些我们必须确保设备的每个零部件都必须触摸到CLEANINGWITHMEANING清洁的意义AMStep1AM自主维护步骤1Sourcesofcontamination污染的源头Ifwecanidentifyandeliminatethesourcesofcontaminationthentheequipmentshallremaininthenewlyrestored,cleanconditionthusreducingforceddeterioration.如果我们可以识别并消除污染的源头，设备将保持在一个新的状态，清洁的状态会减少被动的恶化。

Hardtoaccessarea难以接近的区域Ifwecanidentifyand

eliminatethehardto

accessareasthenwe

canreducethetimetaken

toclean,lubricateand

inspectwhichmakesit

morelikelythatthe

checksaredone如果我们能识别和消除难以接近的区域，那么可以减少清洁、润滑、检查所花的时间

AMStep1-CleaningwithMeaningAM自主维护步骤1-清洁的意义Cleaningshowsuswheretheproblemsare!清洁表明了问题在哪里！OILSSPOTS滴油点BUTWHEREISTHESOURCE?但是源头在哪里？AMStep1-CleaningwithMeaningAM自主维护步骤1－清洁的意义Cleaningallowsustomonitor清洁让我们可以监控Wear&Tear磨损&损坏AMStep1-CleaningwithMeaningAM自主维护步骤1-清洁的意义Temporarysolutions临时措施FindingtheProblems!找到问题！

STARTBYOBSERVINGTHEMACHINEINMOTION Useyoursenses:从用你的感官留意设备的运转开始Listentothemachineforunusualnoises听设备不正常的噪音Seethemachine

anditseffects观察设备和它的运转情况Bealertto

strangesmells注意奇怪的味道

AMStep1-CleaningwithMeaningAM自主维护步骤1-清洁的意义FindingtheProblems!找到问题！

TOUCHTHEMACHINE触摸设备 Forsafe/accessiblesystems(NONexposedmovingparts):基于安全/易懂的系统（不包含裸露运动的部件）Checkforvibration检查震动

(Maynotbepossible–checkforloosenesslater)Checkforheat检查温度Formovingsystemsensure

youISOLATE,thenfollow

uponwhatyouobserved.对于运动部件确保已断开能源后再继续你想观察的。

AMStep1-CleaningwithMeaningAM自主维护步骤1-清洁的意义FindingtheProblems!找到问题

BIGGERPARTS大的零部件Mainoperatingsystem主要的操作系统Movingandturningsystems移动和转向系统Transportsystem输送系统Hydraulicsystem液压系统Heating/coolingsystem加热/冷却系统Compressedairsystem压缩空气系统

BIGSMALLBearings,couplings轴承，联轴器Shafts,brakes轴，刹车抱闸Switches,sensors开关，传感器

etc……等等

SMALLERPARTS小的零部件Nuts,boltsandscrews螺母螺钉螺栓Chainsandlinks链条Springs弹簧Valves,controls&filters阀门控制机构过滤器

AMStep1-CleaningwithMeaningAM自主维护步骤1-清洁的意义Thinkbeforeyoumakeajudgement

在作出判断之前请思考Learnthroughdiscovery!从所发现的来学习

NOTSITTING

ANDTHINKING不是坐在那里想！！！AMStep1-CleaningwithMeaningAM自主维护步骤1-清洁的意义Developacultureoflubricatingimmediately立即养成一个润滑的素养

(OfcourseatthisstageitisstillMaintenancewhowillperform

thelubrication)（当然在这个阶段仍然是维修人员开展润滑工作)Operatorfindsthepr