1、1Total Productive MaintenanceManufacturing 生產部門2 ProcessCertificationTPMQCPCRoot Cause /CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinic ActivityTotal Productive Maintenance ACE Manufacturing Qualifying Level 3 程序驗證程序驗證全面性生產全面性生產維護維護質量診斷程序質量診斷程序圖表圖表根本原因

2、根本原因修正行動修正行動減少生產減少生產準備準備標準化標準化作業作業防誤措施防誤措施市場反饋市場反饋分析分析6S質量診斷質量診斷行動行動全面生產性維護 ACE 生產部門合格水平 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！T

3、PM 全面生產性維護5TPM Key Concept TPM的重要概念 Left neglected. Equipment Breaks Down 如果不重視設備很快就會壞TPMs focus is to prevent problems before equipment breaks.TPM 的焦點是要在設備出故障以前以前防止問題出現。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

4、 Way of Working全面生產性維護是一種全新的工作方式全面生產性維護是一種全新的工作方式7Hidden Defects隱藏的問題隱藏的問題Failures故障故障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、腐蝕變磨損、松馳、泄露、灰塵、污垢、腐蝕變形、

5、原材料粘黏、表面磨損、裂縫、過熱形、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。、震動、噪音及其它不正常現象。Tip of the Iceberg冰山的頂端8Typical Causes of Machine Breakdown 典型的機械故障原因Failure toadd oil.沒有加油Grit and chipsin revolvingor sliding parts旋轉或滑動零件中的砂礫和碎片Contaminationof sensors,contacts and Connectors傳感器、觸敏器、連接器污染Dirt and dust on cooling fan冷

6、卻風扇上有灰塵和污垢ComponentFailure組件失靈I wonder whatsgoing to fail next?我在想下面還會出什么我在想下面還會出什么問題呢？問題呢？9TPM Techniques TPM技術Normal operating Range正常操作范圍正常操作范圍Danger!危險！危險！ Simplify and Document TPM Activities. 簡化并記錄TPM行動 Use visual techniques to indicate whats right / whats wrong. 運用直觀技術來演示什么是 對的/什么是錯的。PM Compl

7、eted? 生產性維護完成了嗎？Pressure gage 壓力計Sight glass 視鏡Arrows for motor rotation and fluid circulation馬達旋轉和潤油指示箭頭markings for spare parts and fluids. 備用零件和潤滑油記號Making PM devices more accessible. 使生產性維護設備更容易獲得 Filters, fittings made more accessible 過濾器、各種裝置Transparent panels to facilitate inspection 明了易讀的儀表盤

8、便于檢查10TPM Benefits TPM的益處 Reduced maintenance costs 減少維護費用 Breakdown maintenance is 10 times more costly than planned maintenance 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 o

9、f 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 time, longer life縮短停工時間，壽命更長1112 TPM Qualifying ActivitiesACE Element Awareness TrainingLock Out/Tag Out awareness training available for all employees (with annual refresher)

10、Operators of high hazard equipment informed of machine specific hazardsAssessment of machine specific safeguarding (SP-008) issuesLock Out/Tag Out Equipment AvailableReview OnlyAction ItemsAssess all Equipment A, B & CImplement written Lock Out/Tag Out procedureWalk around safety check on 100% o

11、f A/B equipmentPM Schedule for 100% of A/B equipmentCleaning on 100% of A/B equipmentTrack downtime historyTop ten downtime equipment identified1212 項TPM 合格行動ACE 內容認知培訓鎖定/標識 認知培訓，針對所有員工（每年的復習進修者）告知高危險設備操作員有關機器的詳細危險機器的特殊防護措施（SP-008）問題評估可用的鎖定/標識設備僅用于檢查行動內容評估所有 A, B & C類設備完成寫好的鎖定/ 標識程序所有 A/B類設備的安全巡

12、查所有 A/B類設備的生產性維護進度表清潔所有A/B類設備追溯停工歷史確認的十大停工設備13PURPOSE of Lockout/Tagout鎖定鎖定/標識的目的標識的目的Lockout/Tagout Review:鎖定鎖定/標識檢查標識檢查14Lockout Device 鎖定設備A lock or other device that utilizes a positive means, to hold an energy isolating device in a safe position and thereby preventing the energizing of a machin

13、e or piece of equipment.一把鎖或其它設備，用于使電源設備隔離裝置處于一安全的狀態，以防止機器或設備的一部分帶電。Lockout/Tagout Review:鎖定鎖定/標識檢查標識檢查15Tagout Definition 標識的定義 The process of securely fastening a tag or prominent warning sign to indicate that both the energy isolating device and the equipment being controlled, be operated. 是將一標簽或

14、明顯的警告標志緊附于設備上 以表明不能不能對電源隔離設備及處于控制下的 設備進行操作。 The tag will also include the name of the person who locked out the equipment.該標簽應有鎖定該裝置的 人的名字。Lockout/Tagout Review:鎖定鎖定/標識檢查標識檢查16NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.決不要從它人處接受鎖定設備的鑰匙。決不要從它人處接受鎖定設備的鑰匙。THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR

15、TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOCK OR TAG.唯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。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:鎖定鎖定/標識檢查標識檢查17ACTION ITEM 1: Assess All Equipment行動內容行動內容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.

16、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 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優先放在正確的設備上。

17、對瓶頸設備給予特殊的關注。Equipment設備設備18 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 alternate 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 alterna

18、te 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-shelf 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/machi

19、nes所有其它設備/機器ACTION ITEM 1: Assess All Equipment (cont.)行動內容行動內容1：評估所有設備（待續）：評估所有設備（待續）19In addition to machine category, create a table listing all machines and additional categories, such 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：Year of manufacture產品的生產年份Type of machine? Condition? (Good / Fair / Poor)機器類型？狀

20、況？（好/一般/差）Does Operator PM process exists (Has a service card been created?)是否有操作員生產性維護程序（是否有服務卡？）Does Maintenance PM process exist (Does a written maintenance task list exist?)是否有維護生產性維護程序（是否有記錄的維護任務表？）Has the machine undergone initial cleaning?機器是否經過最初的清潔？Has machine been assessed for safeguarding

21、 per SP008? (EH&S items)機器是否經過安全裝置SP008評估？（EH&S項）ACTION ITEM 1: Assess All Equipment (cont.)行動內容行動內容1：評估所有設備（待續）：評估所有設備（待續）MACHININGSafety Plan - 2000AREA: 007MACHINE CATAGORYBRASS TAGYEARTYPE EQUIPGEN. COND. GOOD/FAIR/ POORB312488BridgeportGoodB300485HardingeGoodBE1507558Warren Spin PitPoor

22、BE6049187Shadow graphGoodBE7631291Balance controllerGoodB316890BostoGoodB261578BostoGoodB254875LapperGoodB328093OkumaGoodB319891Harrison man. latheGood20Possible Categories:可能的分類： Equipment which retains all of its original functions, accuracy and reliability. ：設備保持所有原來的功能，精確并可靠。 Equipment which has

23、 lost some of its original functions or accuracy. Its output normally meets the required specifications.：設備喪失了一些最初的功能或精確度。其產品符合要求的規范。 Equipment which is no longer accurate or reliable. In order to produce acceptable output, this equipment requires operator intervention well beyond the original level

24、. 設備不再精確或可靠。為了生產出可接受的產品，要求操作員對設備進行超出原有水平的干涉。ACTION ITEM 1: Assess All Equipment (cont.)行動內容行動內容1：評估所有設備（待續）：評估所有設備（待續）21ACTION ITEM 2: Write Machine-Specific Lockout ProceduresLockout procedures must be written and implemented for each machine General procedures are in effect for Sullair Procedures

25、need to be written jointly with facilities maintenance22行動內容 2: 將特殊鎖定程序寫在機器上鎖定程序必須寫在每臺機器上并予以執行 一般程序適用于壽力公司 程序必須與設備維護 共同寫下來23 ACTION ITEM 3/4: Operator Walkaround and PM Schedule on 100% A/BOperator PM defined for 100% of Category A and B machines A book or sheet exists which defines the daily/weekly

26、/monthly Operator PM tasks Include safety equipment operation (guards, limit switches, etc.) in Operator PM.Operator PM conducted faithfully (1 month prior to audit) on all Equipment for which it is defined.Rev: BRevision Date: 3/ 25/98Operator Preventive Maintenance Service CardMachine: Okuma LC-30

27、, 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. Check and fill spindle lube: DTE 24.2. Check and fill air

28、 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 on this sheet.1. Grease chuck fittings, 1 shot.2. Grease

29、1 fitting, 2 shots, both turrets.3. Clean air filter.4. Change air filter: Cat. # 021183.24 行動內容 3/4: 操作員巡查和操作員巡查和 所有所有 A/B類設備的類設備的PM進度表進度表操作員PM定義為所有A、B類機器 應有寫明了操作員每日/周/月的PM任務的書或表 包括安全設備（防護裝置、限定電閘等）操作員嚴格地按要求對所有設備進行生產性維護（在審查前一個月）Rev: BRevision Date: 3/ 25/98Operator Preventive Maintenance Service Car

30、dMachine: 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. Check and fill spindle lube: DTE 24.

31、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 on this sheet.1. Grease chuck fittin

32、gs, 1 shot.2. Grease 1 fitting, 2 shots, both turrets.3. Clean air filter.4. Change air filter: Cat. # 021183.25Make Operator PM effective:Use a “Visible at-a-glance” system (Such as a color-coded PM Status board) within the cell to indicate the actual status of “Operator PM” tasks. Must be easy to

33、understand No book or folder to read ACTION ITEM 3/4: Operator Walk around and PM Schedule on 100% A/B (cont.)AREA:_ - OPERATOR PM STATUS BOARDMonth:_Required PMsDateMachine NameBrass Tag #DailyWeeklyMonthly12345678910Daily = Task #1in PM LogsWeekly = Task #2 in PM Logs (to be done every Wednesday)M

34、onthly = Task #3 in PM Logs (to be performed every 2nd Wednesday of the month)Machine Not Operated or PM Not RequiredEquipment Breakdown26使操作員進行有效的生產性維護: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 必須容易理解 無需翻書或文件夾行動內容 3/4: 操作員巡查和操作員巡查和 所有所有 A/B類設備的類設備的PM進度表進度表（待續）（待續）AREA:_ - OPERATOR PM STATUS B

35、OARDMonth:_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 RequiredEquipment Breakdown27C

36、osmetic Cleaning禁止化裝品禁止化裝品ACTION ITEM 5: Initial Inspect/Clean 100% A/B行動內容 5：初步檢查/清潔所有A/B類設備28 Accessible components cleaned, inspected and repaired 可用的部件已清潔、檢查和修好 PM documentation is reviewed/updated PM文件已檢查/更新 Basic improvements are incorporated to improve maintainability and visual 基本的改進用于提高可維護性和形象 operating condition 操作環境How about that. I didnt even know there was a grease fitting here!那個怎么樣。我甚至不那個怎么樣。我甚至不知道這兒還有個油脂知道這兒還有個油脂裝置！裝置！ACTION ITEM 5: Initial Inspect/Cleaning 100% A/B