1、1Total Productive MaintenanceOFFICE 辦公室2 ProcessCertificationQCPCRoot Cause /CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinic ActivityTotal Productive Maintenance ACE Office Qualifying Level TPM3 程序驗證全面性生產維護質量診斷程序圖表根本原因修正行動減少生產準備標準化作業防誤措施市場反饋分析6S質量診斷活動全

2、面生產性維護 ACE 辦公室合格水平 4Total Productive Maintenance is an equipment management strategy that improves equipment efficiency.全面生產性維護是一種設備管理策略以提高設備效率。Or, in other words.Treating the equipment like it is your own!或者，換句話說.對待設備就象它是你自己的一樣！TPM 全面生產性維護全面生產性維護5TPM Key Concept TPM的重的重要概念要概念 Left neglected. Equipm

3、ent Breaks Down 如果不重視設備很快就會壞TPMs focus is to prevent problems before equipment breaks.TPM 的焦點是要在設備出故障以前防止問題出現。In the past, maintenance focusedon fixing equipment after it broke.過去，維護工作總是集中在設備壞了以后對其進行修理。6Total Productive Maintenance is a New Way of Working全面生產性維護是一種全新的工作方全面生產性維護是一種全新的工作方式式7Hidden Def

4、ects隱藏的問題Failures故障Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw materials,surface damage, cracking, overheating, vibration, noise, and other abnormalities.磨損、松馳、泄露、灰塵、污垢、腐蝕變形、原材料粘黏、表面磨損、裂縫、過熱、震動、噪音及其它不正常現象。Tip of the Iceberg冰山的頂端冰山的頂端8ComponentFailure部件失靈Typic

5、al Causes of Equipment Breakdown典型的設備故障原因典型的設備故障原因Failure to replace toner更換墨盒失敗Paper jam卡紙I wonder whatsgoing to fail next?我想下面還會出什么問題呢？Dirt and contamination灰塵和污染Out of paper缺紙9TPM Benefits TPM的益處的益處 Reduced maintenance costs 減少維護費用 Breakdown maintenance is 10 times more costly than planned mainte

6、nance 故障維修費用是有計劃進行維護費用的10倍以上 Enhanced safety 提高安全性 Find exposed wires, open belts, missing guards, loose hardware 發現暴露在外的電線、松開的安全帶、缺少防護、松開的部件 Reduced waste 減少浪費 Prevents loss of lubricant, compressed air 防止潤滑油、壓縮空氣的浪費 Improved quality 提高品質 Equipment more capable of holding tolerance 設備抗性增強 Less down

7、 time, longer life縮短停工時間，壽命更長10TPM Qualifying Criteria (Business Process/Office)3ACE Element Awareness Training for all employeesoEquipment assessment A,B & CoPM plan for 100% of category “A” equipmentWhats AheadoBRONZE TPM CRITERIAoImplement PM PlanoTrack downtime history for vital machinesoPro

8、cess ManagementoIdentify Key ProcessesoIdentify Waste Elimination OpportunitiesQualifyingAwareness &Baseline11TPM 合格標準 (商業程序/辦公室)3ACE 內容認知培訓，針對所有員工o A,B & C類設備評估o 所有“A”類設備的PM計劃前面是什么？o 銅牌TPM標準o 執行PM計劃o 追溯重要機器的停工歷史記錄o 程序管理o 確定關鍵程序o 確定浪費消減方法合格認知 &基線12Sullair Safety Lockout Program Procedure

9、壽力安全設備鎖定計劃程序壽力安全設備鎖定計劃程序Lockout Procedures:鎖定程序：Actions necessary to lockout a power source of any machine to be repaired, serviced or set-up, where unexpected motion, or an electrical or other energy source, would cause personal injury or equipment damage.在任何機器的電源需要修理、維護或準備的地方都必須進行鎖定，否則意外的動作或其它電源將會

10、引起人身的傷害或設備的損壞。Lockout Tag:鎖定標簽13NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.決不要從它人處接受鎖定設備的鑰匙。THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOCK OR TAG.唯有經授權負責運用鎖或標簽的人員可以拿掉該鎖或標簽。Lockout/Tagout Review:鎖定/標識檢查14ACTION ITEM 1: Assess All Equipment活動活動內容內容1

11、：評估所有設備：評估所有設備By “Equipment” we mean any machine that was a capital expense and has a depreciative value. Or any machine that is important to your cell.所謂“設備”是指任何花費了資金并會貶值的機器。或任何對你的部門重要的機器。We Categorize all Equipment based on how Unique and Critical it is to ensure we focus attention on the right eq

12、uipment first. Pay special attention to bottleneck equipment.我們根據設備的獨特性和重要性對所有設備進行分類，以確保我們的注意力首先放在正確的設備上。對瓶頸設備給予特殊的關注。15?ACTION ITEM 1: Assess All Equipment(cont.) 活動活動內容內容1：評估所有設備：評估所有設備（待續）（待續） Critical equipment for which an alternate machine is not feasible, because:不能用其它設備替代的關鍵設備，因為： No alterna

13、te exists, or 無替代設備，或 The alternate is usually unavailable due to utilization, or 該替代設備通常正被使用而不能獲得，或 It would be too costly/time consuming to transition to the alternate 太貴/需花太多時間進行替換 Equipment for which it is relatively easy to find a replacement or alternate相對容易用其它設備替代的設備 Includes most off-the-she

14、lf equipment 包括最常用的設備 Typically cost $2,500 費用低于$2,500 Standard spare parts (like drive motors) are available off-the-shelf 可獲得的常用標準備件（如驅動馬達） All other equipment/machines所有其它設備/機器 Category B: B類：類：16In addition to machine category, create a table listing all machines and additional categories, such

15、as: 除了機器分類，還應作一表格列出所有機器和附加類別，如： Item description/ID number 物品物品描述描述/ID號號 Category 種類種類 Item Owner 物品物品主人主人Identify equipments title holder and a “local” owner if appropriate確定確定設備名義上的擁有者及一設備名義上的擁有者及一“本地本地”主人，如有必要的話主人，如有必要的話 Department managers signature 部門部門經理的簽名經理的簽名ACTION ITEM 1: Assess All Equipm

16、ent(cont.) 活動活動內容內容1：評估所有設備：評估所有設備（待續）（待續）Department ManagerCategory A/B/C List A/B/C類清單CopierEpson PrinterAir conditionerPersonal Comp.Personal Comp.Personal Comp.Personal Comp.BCACCCCUser NameUser NameUser NameUser NameUser NameUser NameUser NameCo. NameCo. NameCo. NameCo. Name Co. NameCo. NameCo.

17、 Name435653217e76544082318921802345 Item物品 ID# Category類型 Title Holder名義主人 Local Owner本地主人17Example: Office Equipment Assessment WorksheetTotal Productive Maintenance, Office Equipment Assessment WorksheetNote:Evaluation for machine only. Not for networksEquipment nameDept.Equipment ID #Responsible

18、IndividualProductivity1. How often is the equipment used each day? 80% or above5 50-80%3 50% or below22. Is there backup/alternate equipment available? No (one of a kind)5 Yes (another dept.)3 Yes (in dept)13. To what extent will a failure of this equipment affect other office processes? Stops entir

19、e dept. process5 . Do other processes run through this equipment? Slows other dept. processes4 Only affects this machine14. To what extent will a failure of this equipment affect on-time delivery? Decisively5 Somewhat2 Not Significantly1Quality5. How will the processes run on this equipment affect f

20、inal quality of theDecisively5 finished product / service?Somewhat2Not significantly1Maintenance6. What is the average monthly cost of repairs to this equipment?$1000 or more5$0 - $10004Service Contract27. What is the average time it takes to repair this equipment?Over 3 hours5 (Help desk response,

21、if applicable)1 - 3 hours40 - 1 hour2Safety, Environment, Housekeeping8. Do safety enhancements need to be applied? Does the equipment need a housekeeping schedule?Both answers are “yes”5One answer is “yes”3“A” Machine: 32-40none are yes0“B” Machine: 22-31Machine Category: Total Score:“C” Machine: 2

22、1 or less18范例: 辦公室設備評估 工作表全面生產性維護, 辦公室設備評估工作表注意:僅用于機器評估。 不用于網絡系統。設備名稱部門設備ID #負責人員生產力1. 該設備第日使用有多頻繁? 80% 或以上5 50-80%3 50% 或以下22. 有可用的后備/替代設備嗎? 沒有 (其中一種)5 是的 (另一部門)3 是的 (部門內)13. 該設備失靈會在多大范圍內影響其它設備? 阻滯了整個部門的運行5 . 其它設備的運行經過該設備嗎? 減慢了其它部門的運行4 只影響到這臺機器14. 該設備的失靈會在多大范圍內影響正在進行的發送? 很明顯地5 有些2 不明顯1品質5. 該設備的運行將怎

23、樣影響產品/服務的最終品質? 很明顯5有些2不明顯1維護6. 每月花在修理該設備上的平均費用有多少?$1000 或以上5$0 - $10004售后服務27. 平均花多少時間修理該設備?3小時以上5 (Help desk response, if applicable)1 - 3 小時40 - 1 小時2安全、環境和內務管理8. 需要增加安全性嗎? 該設備需要內務管理進度表嗎?答案都是“是” 5一個答案是“是”3“A” 類機器:32-40沒有答案是“是”0“B” 類機器:22-31 機器類型: 總分:“C” 類機器:21 或更少19 ACTION ITEM 2: PM Plan on 100%

24、“A”活動活動內容內容2：針對所有：針對所有A類機器的類機器的PM計劃計劃 Operator PM defined for 100% of Category A machines. 為所有A類機器制定操作員PMqDetermine if there are any “A” machines in your areaq確定你的工作區域是否有A類機器qIf there are, there must be a PM plan:q如果有，應有一個PM計劃：qIn-house 內部qOutside Contractor 外部合約人Rev: BRevision Date: 3/25/98Operator

25、 Preventive Maintenance Service CardMachine: Okuma LC-30, 4 Axis, BT # 3054Daily PM Tasks1. Check running sight.2. Check and fill Waylube: Vactra 2.3. Check tramp oil and scrounger. Empty tramp oil if required.4. Check and fill coolant: PML 9333.Weekly PM Tasks: Do Daily tasks and the following:1. C

26、heck and fill spindle lube: DTE 24.2. Check and fill air lubricator: DTE 24. (Shut off and drain air to fill)3. Check motor fan filter (Change if necessary): Cat. # 030058.4. Check and fill hydraulic tank: DTE 24.5. Check roll filter (Change if needed): Cat. # 027793.Monthly PM Tasks: Do all tasks o

27、n this sheet.1. Grease chuck fittings, 1 shot.2. Grease 1 fitting, 2 shots, both turrets.3. Clean air filter.4. Change air filter: Cat. # 021183.20 ACTION ITEM 2:PM Schedule on 50% A&B(contd) 活動活動內容內容2：針對：針對50%A和和B類機器的類機器的PM進度表進度表（待續）（待續）Following is highly recommended to make Operator PM effect

28、ive: 強烈強烈推薦推薦跟進以確保操作員PM的實施：Use a “Visible at-a-glance” system (Such as a color-coded PM Status board) within the work area to indicate the actual status of “Operator PM” tasks. 使用一眼就能看見的系統 (如使用顏色代碼PM狀態板) 在單元中表明“操作員PM”任務的實際狀態lMust be easy to understandlNo book or folder to readl必須容易理解l無需翻書或文件夾AREA:_

29、- OPERATOR PM STATUS BOARDMonth:_Required PMsDateMachine NameBrass Tag #DailyWeeklyMonthly12345678910Daily = Task #1in PM LogsWeekly = Task #2 in PM Logs (to be done every Wednesday)Monthly = Task #3 in PM Logs (to be performed every 2nd Wednesday of the month)Machine Not Operated or PM Not Required

30、Equipment Breakdown21What is next?下一步是什么？下一步是什么？Complete TPM training of your work group by March 7, 20012001年3月7日前你的工作組應完成TPM培訓Before the end of February, look for a groupwiseannouncement of a “Drivers” Meeting to discussthe necessary resources and logistics for completingqualifying TPM activities在

31、2月底以前，宣布召開“領導層”會議，討論必要的資源和后勤以幫助完成取得合格資格的TPM活動22We want a company that reveres people who design, build and maintain things that never break, rather than people who fix things that break. George DavidUTC Chairman and CEO我們希望公司尊敬那些設計、建造并維持不會壞我們希望公司尊敬那些設計、建造并維持不會壞的東西的人們，而不是那些修理會壞的東西的人們。的東西的人們，而不是那些修理會壞

32、的東西的人們。 George DavidUTC Chairman and CEOSummary 小結小結23Total Productive MaintenanceOFFICE 辦公室24 程序驗證全面性生產維護質量診斷程序圖表根本原因修正行動減少生產準備標準化作業防誤措施市場反饋分析6S質量診斷活動全面生產性維護 ACE 辦公室合格水平 25TPM Key Concept TPM的重的重要概念要概念 Left neglected. Equipment Breaks Down 如果不重視設備很快就會壞TPMs focus is to prevent problems before equipm

33、ent breaks.TPM 的焦點是要在設備出故障以前防止問題出現。In the past, maintenance focusedon fixing equipment after it broke.過去，維護工作總是集中在設備壞了以后對其進行修理。26ACTION ITEM 1: Assess All Equipment活動活動內容內容1：評估所有設備：評估所有設備By “Equipment” we mean any machine that was a capital expense and has a depreciative value. Or any machine that i

34、s important to your cell.所謂“設備”是指任何花費了資金并會貶值的機器。或任何對你的部門重要的機器。We Categorize all Equipment based on how Unique and Critical it is to ensure we focus attention on the right equipment first. Pay special attention to bottleneck equipment.我們根據設備的獨特性和重要性對所有設備進行分類，以確保我們的注意力首先放在正確的設備上。對瓶頸設備給予特殊的關注。27 ACTION ITEM 2: PM Plan on 100% “A”活動活動內容內容2：針對所有：針對所有A類機器的類機器的PM計劃計劃 Operator PM defined for 100% of Category A machines. 為所有A類機器制定操作員PMqDetermine if there are any “A” machines in your areaq確定你的工作區域是否有A類機器qIf there are, there must be a PM plan:q如果有，應有一個PM計劃：qIn-