1、MeasureAnalyzeControlImproveLean Six Sigma全面生產(chǎn)維護(hù) (TPM)TPMTPM 團(tuán)隊(duì)組織設(shè)備綜合利用率OEE TPM 活動步驟RD011202MeasureAnalyzeControlImproveLean Six SigmaTotal Productive Maintenance (TPM)TPMTPM Team OrganizationOverall Equipment Effectiveness TPM PhasesRD011202ControlTotal Productive Maintenance (TPM)3精益6 過程改善流程分析分析控制

2、控制改進(jìn)改進(jìn)定義定義選定題目列出客戶從顧客之聲中列出關(guān)建需求定出項(xiàng)目焦點(diǎn)和重要指標(biāo)完成 PDF測量測量繪制業(yè)務(wù)流程圖繪制價(jià)值流程圖制定數(shù)據(jù)收集計(jì)劃測量系統(tǒng)分析收集數(shù)據(jù)過程能力分析分析分析提出關(guān)鍵因子區(qū)分關(guān)鍵因子驗(yàn)證關(guān)鍵因子評枯每個關(guān)鍵因子對結(jié)果的影響量化機(jī)會根本原因排序?qū)ふ腋驹蜥槍﹃P(guān)鍵因子改進(jìn)改進(jìn)關(guān)鍵因子確認(rèn)發(fā)掘潛在的解決方法選擇方案優(yōu)化方案實(shí)行方案控制控制過程變革和控制制定控制計(jì)劃計(jì)算最終財(cái)務(wù)過程指標(biāo)項(xiàng)目過渡給未來項(xiàng)目管理者項(xiàng)目鑒 別轉(zhuǎn)化機(jī)會測量測量定義定義項(xiàng)目編號工具項(xiàng)目定義表凈現(xiàn)值分析內(nèi)部回報(bào)率分析折算現(xiàn)金流分析 PIP管理過程RACIQuad 表過程圖價(jià)值分析腦力風(fēng)暴投票歸類法柏拉

3、圖因果圖/魚骨圖FMEA查檢表運(yùn)行圖控制圖量具 R&RCp & Cpk供應(yīng)鏈加速器分析多變動圖i盒狀圖交互作用圖回歸分析ANOVAC&E 矩陣圖FMEA腦力風(fēng)暴拉系統(tǒng)減少設(shè)置TPM流程圖標(biāo)桿管理親和圖DOE 假設(shè)檢驗(yàn)力場分析圖樹狀圖甘特圖查檢表運(yùn)行圖柱狀圖散布圖控制圖柏拉圖互動回顧愚巧法Revised 1-12-02ControlTotal Productive Maintenance (TPM)4Lean Six Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemD

4、evelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPr

5、ioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Co

6、ntrols Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureDefineProject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management

7、ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp & CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstor

8、mingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-02ControlTotal Productive Maintenance (TPM)5課程目的u學(xué)習(xí)一種方法以便:n將

9、作業(yè)流程中的起作用的所有生產(chǎn)要素整合為一個單一綜合的衡量值（OEE）;n消除導(dǎo)致設(shè)備故障的因素;n使設(shè)備的養(yǎng)護(hù)清潔更易達(dá)成;n用預(yù)測性保養(yǎng)作為一種檢測工具;n實(shí)施維護(hù)審查ControlTotal Productive Maintenance (TPM)6Learning ObjectivesuLearn a method to:nIntegrate operational productivity factors applicable in process industries in a single comprehensive measurementnEliminate factors co

10、ntributing to equipment failurenImprove accessibility for cleaning and maintaining equipmentnUse predictive maintenance as a diagnostic toolnImplement maintenance auditsControlTotal Productive Maintenance (TPM)7個人學(xué)習(xí)意義u流程作業(yè)和保養(yǎng)最優(yōu)化u一種替代傳統(tǒng)的在故障發(fā)生時檢測并修復(fù)的方法;u一種源頭監(jiān)控和校正的先發(fā)系統(tǒng);u一種基于對影響過程性能的主要因素其因果系統(tǒng)的理解工作策略;Con

11、trolTotal Productive Maintenance (TPM)8Whats in It for Me?uOptimized process operations and maintenanceuA method to replace the traditional approach of detecting and correcting faulty conditions as they occuruA proactive system which monitors and corrects causesuAn operations strategy based on under

12、standing the cause and effect system affecting the major contributors to process performanceControlTotal Productive Maintenance (TPM)9全面生產(chǎn)維護(hù) (TPM)定義:u一種用于監(jiān)控操作,設(shè)備保養(yǎng),消除計(jì)劃外停機(jī),和提高作業(yè)與保養(yǎng)協(xié)調(diào)程度的常識性方法。ControlTotal Productive Maintenance (TPM)10Total Productive Maintenance (TPM)TPM DefinitionuA common sense ap

13、proach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance.ControlTotal Productive Maintenance (TPM)11TPMu通過實(shí)施預(yù)防實(shí)現(xiàn)設(shè)備零故障和零缺陷;u預(yù)防工作將立足于以下方面:n維持正常的生產(chǎn)條件n及早發(fā)現(xiàn)異常n快速反應(yīng)ControlTotal Productive Maintenance (TPM)12TP

14、MuAchieve zero equipment breakdowns and zero defects through preventionuEstablish prevention bynMaintaining normal conditionsnEarly detection of abnormalitiesnQuick responseControlTotal Productive Maintenance (TPM)13傳統(tǒng)的反應(yīng)式維護(hù) 維修部門 “我們只管修理”n執(zhí)行所有的維修作業(yè)n往往是一旦設(shè)備發(fā)生故障充當(dāng)救火員的角色;n負(fù)責(zé)定購和保管所有的工具,備件等物資;n實(shí)施定期檢修 生產(chǎn)部

15、門 ”我們只管使用“n通常不作任何維護(hù)活動n一旦設(shè)備出現(xiàn)故障就與維修部門聯(lián)系n維修作業(yè)中只能停工;n一直用到壞了為止ControlTotal Productive Maintenance (TPM)14Traditional Approach“Re-Active Maintenance”Maintenance “WE FIX”nPerform all maintenance activitiesnPerform “Fire Fighting” maintenance when a machine breakdown occursnOrder and administer all tooling

16、, supplies, etc.nPerform Preventive MaintenanceManufacturing “WE OPERATE”nGenerally does not perform any maintenance activitiesnContacts maintenance when a machine breakdown occursnInactive during maintenance activitiesn“Run it till it breaks”ControlTotal Productive Maintenance (TPM)15主要概念定期保養(yǎng)是一種基于時

17、間長短或使用狀況對設(shè)備進(jìn)行檢修的方法.在指定時間或在使用空檔間對設(shè)備實(shí)施檢修作業(yè)以防止設(shè)備發(fā)生故障.n定期保養(yǎng)計(jì)劃預(yù)測性保養(yǎng)是一種基于設(shè)備狀態(tài)的維護(hù)方法.根據(jù)可視信號或檢測技術(shù)的情況來實(shí)施保養(yǎng)以防止設(shè)備發(fā)生故障.n振動分析n激光探測n超聲波檢測n發(fā)電機(jī)測試n熱感應(yīng)n油況分析ControlTotal Productive Maintenance (TPM)16Key DefinitionsPreventive Maintenance is a time or usage based method of maintaining equipment. Maintenance activities a

18、re performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occurring.nPM SchedulesPredictive Maintenance is a situation based method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagnostic tec

19、hniques to prevent equipment breakdowns from occurring.nVibration AnalysisnLaser MeasuringnUltrasoundnGenerator TestingnThermographynOil AnalysisControlTotal Productive Maintenance (TPM)17現(xiàn)狀分析和團(tuán)隊(duì)組織u評估當(dāng)前的操作條件:n機(jī)器利用率,生產(chǎn)率等;n維修費(fèi)用 (配件和人工)n對實(shí)現(xiàn)TPM的各項(xiàng)工作進(jìn)行優(yōu)先次序u評估潛在TPM倡導(dǎo)者及團(tuán)隊(duì)成員的實(shí)力u挑選TPM倡導(dǎo)者及團(tuán)隊(duì)成員n建立初始的實(shí)施專門小組n確定團(tuán)

20、隊(duì)目標(biāo)ControlTotal Productive Maintenance (TPM)18Present State Analysisand Team OrganizationuAssess Current Operating ConditionsnMachine utilization, productivity, etc.nMaintenance repair costs (parts and labor)nPrioritize order of TPM effortsuAssess capabilities of potential TPM Champions and Team Mem

21、bersuSelect TPM Champion and Team MembersnEstablish initial kick-off workshopnEstablish team goalControlTotal Productive Maintenance (TPM)19典型的設(shè)備評價(jià)指標(biāo)u利用率: 設(shè)備實(shí)際運(yùn)轉(zhuǎn)時間與總的可利用時間的比率;n= 實(shí)際運(yùn)行時間/可運(yùn)行時間u效率: 實(shí)際產(chǎn)量與標(biāo)準(zhǔn)產(chǎn)量的比率n= (實(shí)際產(chǎn)量/小時)/(標(biāo)準(zhǔn)產(chǎn)量/小時)u產(chǎn)出: 用一特定時間段的產(chǎn)量來衡量n= 磅/小時, 件數(shù)/小時ControlTotal Productive Maintenance (TP

22、M)20Typical Operational Process MeasurementsuUtilization: The ratio of equipment actual operating time to the total available operating timen= Actual Operating Time/Available TimeuEfficiency: The ratio of actual product produced to a standardn= (Actual Parts/Hour)/(Standard Part/Hour)uOutput: Measur

23、e of output over a specified time periodn= lbs/hr, pieces/hrControlTotal Productive Maintenance (TPM)21設(shè)備綜合利用率OEEu設(shè)備綜合利用率（OEE）是衡量一臺設(shè)備按計(jì)劃速度生產(chǎn)出合格產(chǎn)品的時間占全部時間的百分比.ControlTotal Productive Maintenance (TPM)22Overall Equipment EffectivenessuOverall Equipment Effectiveness (OEE) is the measure of the percent

24、 of time a piece of equipment is producing quality product at the designed rate.ControlTotal Productive Maintenance (TPM)23OEE分解:六大浪費(fèi)故障及輕微故障故障及輕微故障使設(shè)備中斷運(yùn)行的時間超過10分鐘的故障或者中斷時間少于10分鐘的輕微故障.設(shè)置時間浪費(fèi)設(shè)置時間浪費(fèi)任何與設(shè)備調(diào)整,裝配,清潔相關(guān)的作業(yè).機(jī)器空轉(zhuǎn)浪費(fèi)機(jī)器空轉(zhuǎn)浪費(fèi)設(shè)備在運(yùn)轉(zhuǎn)卻沒有用來生產(chǎn)產(chǎn)品所耗用的時間.速度浪費(fèi)速度浪費(fèi)由于設(shè)備或產(chǎn)品的異常造成設(shè)備以低于標(biāo)準(zhǔn)速度或所設(shè)定的速度運(yùn)轉(zhuǎn).品質(zhì)原因浪費(fèi)品質(zhì)原因浪費(fèi)為

25、確保設(shè)備產(chǎn)出品的品質(zhì)而采取相關(guān)的作業(yè)(過程中檢查). 返工浪費(fèi)返工浪費(fèi)用于返修產(chǎn)品或生產(chǎn)出報(bào)廢產(chǎn)品所耗用的時間.ControlTotal Productive Maintenance (TPM)24OEE Breakdown: The Six Big LossesBreakdowns and Minor StoppagesMalfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages)SetupAny a

26、ctivity related to equipment changeover, setup, or cleaning.IdlingTime equipment is running but not producing product.Speed LossesEquipment operating at less than standard or design speed due to equipment/product abnormalityQuality FactorsActivities related to ensuring the quality of the product pro

27、duced on the equipment (in-process checks).Rework LossesThe time taken to re-process product or time take to produce un-usable product.ControlTotal Productive Maintenance (TPM)25六大浪費(fèi)的識別練習(xí)識別損失類別12345678910機(jī)器A在下午1點(diǎn)鐘完成一產(chǎn)品裝配而在下午2:27開始另一產(chǎn)品的裝配工作現(xiàn)象由于電氣故障機(jī)器A的運(yùn)轉(zhuǎn)中斷31分鐘過程中的質(zhì)量檢查耗時22分鐘機(jī)器B上的小裝置裝卸時間為4分鐘由于機(jī)械故障機(jī)器X運(yùn)轉(zhuǎn)

28、中斷8分鐘機(jī)器Z的清潔時間為47分鐘工件被軋住造成機(jī)器C中斷3分鐘從取樣到送至實(shí)驗(yàn)室耗時32分鐘機(jī)器Z返修200個工件由于機(jī)油線路泄漏機(jī)器D僅能以每小時加工100片產(chǎn)品的速度運(yùn)行達(dá)不到125片的標(biāo)準(zhǔn) ControlTotal Productive Maintenance (TPM)26Six Big Losses Identification Exercise SCENARIO LOSS IDENTIFICATION 1. Machine A operation is interrupted by an electrical problem for 31 minutes 2. An in-pr

29、ocess quality check takes 22 minutes 3. Load & unload time between widgets on machine B is 4 minutes 4. Machine X operation is interrupted of 8 minutes due to a mechanical problem 5. Cleaning time on machine Z is 47 minutes 6. Jammed piece causes machine C stoppage of 3 minutes 7. Machine A comp

30、letes a load at 1:00 pm and begins another load (different product) at 2:27 pm 8. A sample is taken and transported to the lab taking 32 minutes 9. 200 pieces are re-processed on machine Z 10. Machine D runs at 100 pc/hr not 125 pc/hr due to leaky oil lines ControlTotal Productive Maintenance (TPM)2

31、7OEE的計(jì)算原理承載時間 (LT)設(shè)備運(yùn)轉(zhuǎn)總的可利用時間 = 40 hrs可用水平(AL)運(yùn)行水平 (OL)質(zhì)量水平 (QL)OEE73% x 91% x 80% 26.3 - 3.1 - 2.1 = 80%26.3 28.9 - 1.5 - 1.1 = 91%28.9質(zhì)量原因機(jī)器故障及輕微故障, 行政事務(wù)/非作業(yè)時間機(jī)器設(shè)置與調(diào)整速度損失機(jī)器空轉(zhuǎn)返工及報(bào)廢 40 - 3.1 - 3.8 - 4.2 = 73%40OEE = 53%AL HRS = 40 - 3.1 - 3.8 - 4.2 = 28.9 hrsOL HRS = 28.9 - 3.1 - 1.1 = 26.3 hrsQL HR

32、S = 26.3 - 3.1 - 2.1 = 21.1 hrsControlTotal Productive Maintenance (TPM)28Calculating OEE ElementsLoading Time (LT)Total Hours Available for Equipment Operation = 40 hrsAvailabilityLevel (AL)OperatingLevel (OL)QualityLevel (QL)OEE73% x 91% x 80% 26.3 - 3.1 - 2.1 = 80%26.3 28.9 - 1.5 - 1.1 = 91%28.9Q

33、ualityFactorsBreakdownsMinor Stops, and Admin.SetupSpeed LossesIdlingRework andScrap 40 - 3.1 - 3.8 - 4.2 = 73%40OEE = 53%AL HRS = 40 - 3.1 - 3.8 - 4.2 = 28.9 hrsOL HRS = 28.9 - 3.1 - 1.1 = 26.3 hrsQL HRS = 26.3 - 3.1 - 2.1 = 21.1 hrsControlTotal Productive Maintenance (TPM)29世界級的OEE性能水平承載時間承載時間 (LT

34、)同步計(jì)劃運(yùn)轉(zhuǎn)時間及生產(chǎn)性防護(hù)時間同步計(jì)劃運(yùn)轉(zhuǎn)時間及生產(chǎn)性防護(hù)時間可用水平可用水平 (AL)運(yùn)行水平運(yùn)行水平 (OL)質(zhì)量水平質(zhì)量水平 (QL)OEE90% x 95% x 99%質(zhì)量原因機(jī)器故障及輕微故障, 行政事務(wù)/非作業(yè)時間機(jī)器設(shè)置與調(diào)整速度損失機(jī)器空轉(zhuǎn)返工及報(bào)廢OEE = 85% 是世界級的性能水平AL始終保持在始終保持在 90%以上以上OL維持在維持在 95%以上以上QL不低于不低于 99%ControlTotal Productive Maintenance (TPM)30World Class OEE PerformanceLoading Time (LT)Operation T

35、ime and PM Time is scheduled synchronizing the twoAvailabilityLevel (AL)OperatingLevel (OL)QualityLevel (QL)OEE90% x 95% x 99%QualityFactorsBreakdownsMinor Stops, and Admin.SetupSpeed LossesIdlingReworkand ScrapOEE = 85% is World Class PerformanceThe AL is consistently kept at or above 90%The OL is

36、maintained at or above 95%The QL is at or above 99%ControlTotal Productive Maintenance (TPM)31階段階段 I階段階段 II階段階段 III階段階段 IVTPM 階段ControlTotal Productive Maintenance (TPM)32PHASE IPHASE IIPHASE IIIPHASE IVTPM PhasesControlTotal Productive Maintenance (TPM)33六大團(tuán)隊(duì)活動1. 通過小規(guī)模的小組活動來提高機(jī)器的正常運(yùn)行時間,消除造成停工的主要根源:

37、n機(jī)器的啟動損失n機(jī)器的故障損失n待料損失和生產(chǎn)安排不當(dāng)帶來的停機(jī)損失2. 使操作員熟練地參與如潤滑,清潔, 故障檢驗(yàn)等基本的保養(yǎng)維護(hù). ControlTotal Productive Maintenance (TPM)34Six Team Activities1. Use small group activities to improve machine uptime by eliminating the major sources of downtime.nStartup LossesnBreakdown LossesnMaterial and Scheduling Losses2. In

38、volve the machine operators as well as skilled trades in basic preventative maintenance such as lubrication, cleaning, and inspection for defects. ControlTotal Productive Maintenance (TPM)35六大團(tuán)隊(duì)活動(續(xù)上頁)3. 使用諸如振動分析類的預(yù)測工具擯棄過去那種反應(yīng)式的維護(hù)模式4. 增強(qiáng)對設(shè)備的認(rèn)知和了解以提高生產(chǎn)效能,減少停工時間;5. 使供應(yīng)管理和生產(chǎn)調(diào)度協(xié)同工作以確保持續(xù)穩(wěn)定的原材料供應(yīng),避免停機(jī)待料;6

39、. 規(guī)劃人員配備以確保瓶頸設(shè)備處的滿員運(yùn)作ControlTotal Productive Maintenance (TPM)36Six Team Activities (Cont.)3. Utilize predictive tools such as vibration analysis to move past reactive type maintenance4. Increase awareness and knowledge of equipment to improve productivity and reduce downtime5. Work with Supply Mana

40、gement and Production Control to insure a constant flow of raw material is available to preclude idling.6. Develop manning schedules that insure that bottleneck machines are fully staffedControlTotal Productive Maintenance (TPM)37TPM的益處u提升操作員的參與感u使設(shè)備恢復(fù)至更高的性能水平u發(fā)現(xiàn)并消除早期的設(shè)備隱患u減少總的制造成本u減少浪費(fèi) u在保養(yǎng)設(shè)備方面樹立榮譽(yù)

41、感u促進(jìn)維護(hù)和生產(chǎn)部門之間的相互尊重與合作 ControlTotal Productive Maintenance (TPM)38Benefits of TPMuPromotes operator involvementuRestores equipment to a higher performance leveluUncover and eliminate premature equipment failuresuReduce total manufacturing costsuReduces waste uBuilds a sense of pride in maintaining th

42、e equipmentuPromotes cooperation and respect between maintenance and production ControlTotal Productive Maintenance (TPM)39職責(zé)范圍u精益6Sigma團(tuán)隊(duì)u倡導(dǎo)者/發(fā)起人uTPM團(tuán)隊(duì)n操作員n現(xiàn)場主管n維護(hù)人員ControlTotal Productive Maintenance (TPM)40Areas of ResponsibilityuLean Six Sigma TeamuChampion/SponsoruTPM TeamnOperatornSupervisornM

43、aintenanceControlTotal Productive Maintenance (TPM)41精益6Sigma團(tuán)隊(duì)的任務(wù)u確定一個TPM項(xiàng)目的需求u收集有關(guān)維護(hù)成本,延遲(時延或操作延遲,設(shè)備利用率以及質(zhì)量問題的歷史數(shù)據(jù)u與操作員進(jìn)行深入溝通以了解他們的期望ControlTotal Productive Maintenance (TPM)42Lean Six Sigma Team RoleuDetermine the need for a TPM ProjectuGather history of maintenance cost, delay, machine availabil

44、ity, and quality problemsuInterview Operators to get their prospectiveControlTotal Productive Maintenance (TPM)43u現(xiàn)場活動n組成TPM團(tuán)隊(duì)l負(fù)責(zé)設(shè)備維護(hù)的人員l操作員l一線管理人員n準(zhǔn)備必要的裝備n幫助TPM團(tuán)隊(duì)診斷異常n協(xié)助跨功能培訓(xùn)n收集整理故障標(biāo)牌的拷貝并生成工作明細(xì)表n提供人力資源方面的支持精益6Sigma團(tuán)隊(duì)的任務(wù)ControlTotal Productive Maintenance (TPM)44Lean Six Sigma Team RoleuOn floor act

45、ivitiesnAssemble the TPM TeamlMaintenance personnellOperatorslFirst line supervisionnProvide necessary equipmentnHelp team diagnose abnormalitiesnAssist skilled tradesnCollect copies of defect tags and generate a work listnProvide people resourcesControlTotal Productive Maintenance (TPM)45倡導(dǎo)者/發(fā)起人的角色

46、u一旦完成現(xiàn)場工作,接下來將:n形成工作任務(wù)并跟蹤其完成情況n協(xié)助建立和引入正確的定期維護(hù)明細(xì)表n協(xié)助維持改善結(jié)果n評估設(shè)備綜合利用率OEEn展示TPM的改善的成就ControlTotal Productive Maintenance (TPM)46Champion/Sponsor RoleuUpon Completion of On Floor EventnGenerate and track completion of work ordersnAssist in creation and posting of accurate Periodic Maintenance List nAssi

47、st in sustaining the gainsnEvaluate Overall Equipment EffectivenessnDisplay TPM improvementsControlTotal Productive Maintenance (TPM)47現(xiàn)場主管的角色u指導(dǎo)并推廣TPM概念u監(jiān)控現(xiàn)場的設(shè)備管理,保養(yǎng)及機(jī)器清潔工作的進(jìn)行u激發(fā)操作員的主人翁意識u對操作員授權(quán)u為TPM活動提供時間方面的準(zhǔn)備u促進(jìn)生產(chǎn)與維護(hù)雙方的合作ControlTotal Productive Maintenance (TPM)48Supervisors RoleuCoach and promot

48、e TPM ConceptsuMonitor ongoing housekeeping and machine cleanlinessuPromote Operator ownershipuEmpower Operators uProvide time for TPM activitiesuPromote cooperation between Production and MaintenanceControlTotal Productive Maintenance (TPM)49維護(hù)人員的角色“專業(yè)的管理者”u有計(jì)劃的實(shí)施所有的定期保養(yǎng)并根據(jù)需要采取維修措施;u使用振動分析,磨損度分析,熱感

49、應(yīng)等預(yù)測工具;u建立維護(hù)設(shè)備的保養(yǎng)記錄u與操作員協(xié)同工作并提供技術(shù)支持u執(zhí)行設(shè)備大修,綜合調(diào)試u負(fù)責(zé)執(zhí)行一些特殊技能的任務(wù),風(fēng)險(xiǎn)安全性高的作業(yè)u促進(jìn)TPMControlTotal Productive Maintenance (TPM)50Maintenance Role“The Specialized Caretakers”uPerform all planned preventative maintenance and take corrective action as neededuUse predictive tools such as vibration analysis, wear

50、 particle analysis, and thermographyuDocument equipment maintenance historyuCooperate with Operators and provide technical assistanceuPerform equipment overhaul, complex adjustmentsuProvide special skill tasks, high safety risk tasksuPromote TPM ControlTotal Productive Maintenance (TPM)51操作員角色“一線管理者

51、”u清潔和缺陷檢查u執(zhí)行基本的潤滑,多點(diǎn)檢測的工作u按照核準(zhǔn)清單的項(xiàng)目進(jìn)行定期保養(yǎng)u按計(jì)劃執(zhí)行日常清潔和整理u識別剛剛發(fā)生的設(shè)備異常u根據(jù)需要協(xié)助維護(hù)人員進(jìn)行維修u執(zhí)行基本的調(diào)試工作u改善提案u促進(jìn)TPMControlTotal Productive Maintenance (TPM)52Operators Role“The First Line Caretaker”uClean and inspect for defectsuPerform basic lubrication, multi-point inspectionuPerform Periodic Maintenance per a

52、pproved ListuPerform routine cleaning and housekeeping as scheduleduIdentify equipment defects as they ariseuAssist Maintenance with repairs upon requestuPerform basic adjustmentsuSuggest improvementsuPromote TPM ControlTotal Productive Maintenance (TPM)53全面生產(chǎn)維護(hù)的七大步驟1. 完成初始的機(jī)器清潔和檢查2. 識別機(jī)器的缺陷和泄漏并加以標(biāo)示

53、3. 建立操作員及維護(hù)人員的定期檢測的PM計(jì)劃4. 指導(dǎo)操作員使用正確的保養(yǎng)方法5. 指導(dǎo)維護(hù)人員使用正確的保養(yǎng)方法6. 貫徹現(xiàn)場5S管理和組織活動7. 監(jiān)控OEE并鼓勵大家合作ControlTotal Productive Maintenance (TPM)54The 7 Steps of Total Productive Maintenance1. Perform initial machine cleaning and inspection2. Identify and tag machine defects and leaks3. Develop Operator and Mainte

54、nance PMs4. Instruct Operators in proper PM techniques5. Instruct Maintenance Staff in proper PM techniques6. Implement 5S Housekeeping and Organization7. Monitor OEE and encourage cooperationControlTotal Productive Maintenance (TPM)55TPM 安全常識u遵守/使用n停工現(xiàn)場標(biāo)牌警示程序n正確的起重方法n用電安全操作規(guī)范n勞保裝備l手套l工作鞋 l護(hù)目鏡l防塵口罩

55、l耳塞ControlTotal Productive Maintenance (TPM)56TPM Safety HabitsuFollow/UsenLockout Tagout ProcedurenProper Lifting TechniquesnElectrical Safety GuidelinesnPersonal Protective EquipmentlGloveslSafety Shoes lGoggleslRespirators lHearing ProtectionControlTotal Productive Maintenance (TPM)57TPM 步驟1初始的機(jī)器

56、清潔和檢查初始的機(jī)器清潔和檢查u目的:識別需修理處并標(biāo)示缺陷u執(zhí)行:n徹底清潔機(jī)器-團(tuán)隊(duì)所有成員參與n并將所有需要維修的項(xiàng)目標(biāo)示并記錄ControlTotal Productive Maintenance (TPM)58TPM Step 1Initial Machine InspectionuPurpose: To Identify needed repairs and tag defectsuExecution:nClean machine thoroughly done by all team membersnTag and record all repairs needed in a p

57、roject notebookControlTotal Productive Maintenance (TPM)59TPM 步驟1“現(xiàn)場活動”u徹底的清潔工作包括:n清除所有的碎屑及其他殘余物n徹底地去除油污n調(diào)節(jié)壓縮空氣n更換過濾器,潤滑劑等n潤滑移動部件及接頭處n清理不必要的使用工具,五金器具及備件等u“你的雙手肯定會臟兮兮的!”ControlTotal Productive Maintenance (TPM)60TPM Step 1“On Floor Activities”uA Thorough Cleaning Includes:nRemoving all chips and othe

58、r debrisnThorough DegreasingnCompressed air for controlsnChanging filters, lubricants, etc.nLubricating moving parts and jointsnRemoving unnecessary tooling, hardware, supplies, etc.u“You have to get your hands dirty!”ControlTotal Productive Maintenance (TPM)61TPM 步驟1“現(xiàn)場活動”u維修項(xiàng)標(biāo)示色碼 u標(biāo)簽上須標(biāo)示的信息:n機(jī)器的資產(chǎn)

59、編號n機(jī)器位置及故障位置n投入使用的日期及使用人n機(jī)油機(jī)油泄漏泄漏橙色橙色n冷卻液泄漏冷卻液泄漏綠色綠色n空氣泄漏空氣泄漏 黃色黃色n機(jī)器故障機(jī)器故障 粉紅色粉紅色n電氣問題電氣問題-藍(lán)色藍(lán)色ControlTotal Productive Maintenance (TPM)62TPM Step 1“On Floor Activities”uRepair Tag Color Codes uInformation Needed on TagsnAsset number of machinenLocation and relative position of defect on machinenNa

60、me of originator and datenOil Leaks - OrangenCoolant Leaks - GreennAir Leaks - YellownMachine Defects - PinknElectrical Problems - BlueControlTotal Productive Maintenance (TPM)63關(guān)注TPM清潔效果 降低停機(jī)時間70%u之前 砂粒及碎屑很嚴(yán)重n無法調(diào)試n運(yùn)行速度降低n故障接連發(fā)生u之后 跨功能工作的成果 n更換缺損的零部件n調(diào)試校正n恢復(fù)至設(shè)計(jì)速度且保持品質(zhì)ControlTotal Productive Maintenance (TPM)64Focused TPM Cleani