AutonomousMaintenance自主維修

Guidelines指導方針NHAGNHCETherearetwotypesofautonomousactivities:oneisfocusedontheareaswithintensivemachineryandtheotherontheareaswithahighleveloflaborcontent.有兩種自主維修活動，一是重點放在加強機器區域，另一個是勞力較多的區域。TheactivityregardingthemachineryiscalledAutonomous

MaintenanceandtheactivityregardingtheorganizationoftheworkareaiscalledWorkplaceOrganization關于機器方面的活動叫自主維修，關于工作區域組織的活動叫工作場所組織。AutonomousMaintenance自主維修Theautonomousmaintenanceispartofthoseactivitiesthathasasthemainscopetopreventbreakdownsandmicrofailuresduetolackofbasicconditionsofthemachines.自主維修是那些活動的一部分，這些活動能夠預防由于機器基本條件缺乏造成的損壞和小故障。Theautonomousmaintenanceisnotatechnicalactivity,liketheprofessionalmaintenance,butitmustbelearnedandappliedbyallthepeoplethatinteracteverydaywiththemachines.It’sbasedonthecompetenciesoftheoperatorsandusingthefivesensesandverysimpletoolslikepaintbrushestoeliminatethedirt,plastictoprotectthemachineryetc.自主維修不是一種技術活動，像專業維修，但是每天使用機器的人都要學會應用此自主維修技術。它是在操作工能力基礎上的，用五官，使用很簡單的工具，如用油漆刷來清除污漬，用塑料保護機器等。WhatisAM?(1/2)什么是自主維修？ThetypicaloperationsofAMarecleaning,lubrication,adjustmentoffasteners,parameterscontrol,temperaturecontrol,noiseandvibrationcontrol,minorrepairsandminorimprovements.自主維修典型的操作是清潔，上油，調節閥，參數控制，溫度控制，噪音和振動控制，小修復和小改善。TheAMisasystematicapproachtowardsthemachineryimprovementwiththeobjectivetoautonomouslymanage,bytheproductionoperators,theinspections,thecontrolandrestorationofthebasicconditionsofthemachineryeliminatingthesourcesofdirt,throughastrictapplicationandacontinuousimprovementofthestandards.自主維修是進行機器改善的系統方法，擁有自主管理的目標，由生產操作工清除污漬來源，通過嚴格遵守運用不斷改善的標準，進行檢查，控制和恢復機器的基本條件。RegardingAMandPM,uptostep3,it’sveryimportanttoalwayskeepseparatedthepreventiveactivitiesamongstthetwopillars.關于自主維修和專業維修，一直到步驟3，要一直將兩支柱中的預防性維修分開很重要。WhatisAM?(2/2)什么是自主維修？Themachinescanbreakbecauseofdeterioration,increasingofthestressthattheyshouldsupport,causedbythelossofbasicconditions.Likewisetheycanbreakduetohumanerrorsortodesignerrors.

機器可能損壞，是因為磨損，所能承受的壓力增加，基本條件缺乏造成的。同樣，也可以是人為失誤或設計錯誤造成的。Whydothemachinesbreak?(1/2)機器為什么會損壞呢？BREAKDOWN損壞DETERIORATION磨損EXCESSIVESOLICITATIONS額外的引發SCARCEROBUSTNESS不夠耐用1Lackofmaintainingthebasicconditions維修基本條件缺乏23465Lackofobservancyoftheoperatingconditions不遵守操作條件Norestorationoftheanomalies沒有對異物進行恢復Designweakness設計不足Badcompetenciesofoperatorsandmaintenancepeople操作工和維修人員的能力差Externalinfluences:material,spareparts,environmentecc.外部影響：材料，備用零件，環境等。Whydothemachinesbreak?(2/2)機器為什么會損壞？Thedeterioration

happensastimegoesoncausedbyabadmaintenancenotableto“maintain”thebasicconditionsorbythebadcompetenciesoftheoperatorswhomdonotperformcorrectlytheinspections.由于維護不當，不能維護基本條件或能力差的操作工不能正確的完成檢查，時間久了就會發生磨損。Theincreaseofstressandtheexcessivesolicitationsareduetooperatingerrors(badcompetenciesoftheoperators),badinterventionsorduetothefactthattheoperatingconditionsarenotstrictlyobservedbytheoperatorsandofthenonobservanceofthebasicconditions.由于操作失誤（操作工能力差），不良干涉或操作工不能嚴格遵守操作條件及不遵守基本條件，導致壓力增加，額外的引發出現。Thescarcerobustnessofthemachineryistheresultsoferrorsorweaknessofthedesignsofthemachinesorsinglecomponents,ofconstructionorinstallationerrors.Toavoidthedeteriorationofthemachinery,itisnecessarytoassurethemaintenanceofthebasicconditions.Thisispossiblethroughthepreventivemaintenance,activitiescarriedoutbytheAMandPMpillars.機器不耐用是因為機器零件的設計、構造錯誤或不足，或安裝錯誤。為了避免機器磨損，保證機器的基本條件很重要。可以開展由AM和PM支柱執行的維修活動。Inordertoavoiderrorsdonebyoperatorsormaintenancepeople,whocangeneratetheincreasingofstress,trainingmustbedone.為了避免由能產生壓力增加的操作工或維修人員造成的失誤，必須要進行培訓。Toavoiderrorsduetodesignweaknesses,theEarlyEquipmentManagementpillartakesparttosolvetheissues.為了避免由于設計不足造成的錯誤，設備初期管理支柱要加入解決此問題。AM:Objectives自主維護：目的Inthefirstphase,theobjectiveoftheAMisthemaintenanceofthe

basicconditionsofthemachinery.Thisisachievableassuringthecorrectoperatingstandardsofthemachinery,thecleanliness,thelubricationandsafety.第一階段中，AM的目的是維護機器的基本條件。保證正確的機器操作標準，確保清潔，潤滑和安全，這是可以實現的。ThefinalscopeoftheAMistostabilizetheconditionsofthemachinery,improvetheirreliabilityandtoobtainasaresultthelengtheningoftheirlifetime.AM的最終目標是穩定機器的條件，改善其可靠性并實現機器使用壽命的延長。Thispresupposesthedefinitionandthecontinuousimprovementofthemaintenancestandardsandtheincreaseofthecompetenciesoftheoperatorsintermsofknowledgeofthemachines.AveryimportanteffectoftheAMisthequalityimprovementofthemachineregardingtheproduct.這預示著維修標準的定義和不斷改善，及操作工就機器方面能力的增加。自主維修的一個非常重要的作用是涉及生產的機器質量改善。Initialcleaning&inspection初步清潔和檢查Countermeasuresagainstsourcesofcontamination處理污染來源的對策Initialstandards初步標準Generalinspection全面檢查Autonomousinspection自主檢查Improvementofstandards(workplaceorganization&housekeeping)工作場所組織和設備管理、保養標準的改進Full-scaleapplicationoftheautonomousmaintenancesystem全面貫徹自主維護系統TheSevenStepsofAutonomousMaintenance–AM自主維護的7個步驟Step1Step2Step3Step4Step5Step6Step7The7steps7個步驟Thescopeofthefirstthreestepsistogeneratechangesinthemachines,passingfromconditionsofdirtiness,ofdifficultyincleaningthemachines,hazardousness,slowness,unreliabilityandofbreakdownsandstoppagestoaconditionofcleanliness,safety,reliability,zerostoppagesandzerobreakdowns.前三步是為了改變機器，解決污穢情況及難以清洗的機器問題，將危險，緩慢，不可靠和損壞，停頓情況轉變為清潔，安全，可靠，零停頓和零損壞狀態。

Thestep2isthemostcriticaloneforobtainingadvantagesthatderivefromAM.Theactivitiesofthefirsttwostepsaretypicallyofareactiveapproach.Theapplicationofsteps1-3istheKEYtodeterminethebasicconditionsofthemachine.第二步是AM取得優勢的最關鍵步驟，前兩步是回應方法的典型代表。步驟1到3的運用是決定機器基本狀態的關鍵。The7stepsThefourthandfifthsteparefinalizedtogenerateachangeinthepeople,infacttheinspectionsdonedirectlybytheoperatorscreatescomprehensionandassumptionofresponsibilitytowardswhatandhowtocontrol,eventowardsquality,andmakesworkeasier.Theoperatorsgraduallyassumethecapabilitytoaccomplishautonomouslythemaintenanceactivitiesjustlikeaparentwoulddowiththehealthofhischildrencallingthedoctor,thatcanbecomparedtothemaintenancetechnicianincaseofnecessityforproblemsonthemachinery.It’simportanttoconsiderthefactthattheimplementationofstep4

isexpensiveintermsoftimeandmoney.It’simportanttopayattentiontothecostbenefitofthisstepinordertojustifytheimplementation.Theactivitiesofsteps3-4-5aretypicallyofapreventiveapproach.第4步和第5步是為了改變人，實際上由操作工直接執行的檢查創造出對要控制什么，該如何控制及對質量的理解和責任，并且是工作變得更加容易。漸漸地，操作工就有責任，有能力自主完成維修活動，就像父母為了孩子的健康而找醫生一樣，這可以與萬一機器出現問題，必須要找維修技術員相比。就時間和金錢而言，考慮執行步驟4的花費很大很重要。為了證明此步的執行是有效的，注意成本收益很重要。步驟3、4、5是預防性方法的典型代表。Thescopeofthesixthandseventhstepsistogeneratealong-lastingchangeinthemaintenancemanagementacrossanewmanagementsystemofautonomousactivitieswheretheworkerisresponsibleforhisareaintermsofqualityandreliabilityofthemachines.第6步和第7步是為了對維修管理進行長期的改變，形成新的自主活動管理系統，該活動中，工人們負責管理自己區域內的機器的品質和可靠性。Contentsofthe7steps–AM

自主維修的7個步驟的內容StepContentsOfStep步驟的內容0Educationofmachinefunction&condition對機器性能和狀態的學習1InitialCleaning&Inspection初步的清潔和檢查2Countermeasurestoeliminatesourcesofcontaminationand“hardtoaccess”areas清除污染來源和難以清洗區域的對策3Developprovisionalstandardsforcleaning,lubrication&tightening制定清洗，上油和上緊的臨時標準4GeneralInspection–Training&Instructionofthefinalizedstandards全面檢查-對最終標準的培訓和指導5AutonomousInspection自主檢查6Reorganizingworkplace&Standardization重組工作場所并標準化7FullImplementationofAutonomousMaintenance全面貫徹自主維修Motivation動機MachineChange機器改變PeopleChange人員改變WorkplaceChange工作場所改變RestorationofBasicConditions基本狀態的恢復PreventionofDeterioration預防磨損OptimizeStandardizeSelfManagement使自身管理最優化，標準化2ELIMINATIONOFCAUSESOFLOSS清除損失原因3STANDARDCLEANINGLUBRICATION標準清洗潤滑油4GENERALINSPECTION全面檢查5INDEPENDENTINSPECTION獨立檢查6AREACONTROLANDMANAGEMENT區域控制和管理7COMPLETEAPPLICATIONOFAUTONOMOUSMAINTENANCE自主維護的全面運用INITIALCLEANING初步清潔1THOROUGHELIMINATIONOFDIRTFROMPLANTS對工廠污垢的徹底清除LEARNINGTHAT‘CLEANINGISINSPECTING’學習“清潔就檢查”REMOVALOFCAUSESOFDIRT/LOSSES除去污垢/損失原因REMOVALOFOBSTACLESTOACTIVITIES除去阻礙活動的障礙物REDUCTIONOFCLEANING,LUBRICATIONTIMES減少清潔，上油時間DEFINECLEAR,SIMPLECLEANING,LUBRICATION,TIGHTENINGCONTROLSTANDARDS;SPECIFYTIMESANDFREQUENCY定義清潔，簡單的清洗；固定控制標準；指定次數和頻率IMPROVETHEABILITYTOMAKEAGENERALINSPECTIONOFTHEPLANTACCORDINGTOSTANDARDSANDMANUALS根據標準和指南來提高全面檢查工廠的能力IMPROVETHEABILITYTOCARRYOUTINDEPENDENTINSPECTION,PREVENTIVEMAINTENANCECYCLESANDTOUSETHECHECK-LISTS提高執行獨立檢查，預防性維修周期，使用核對表的能力STANDARDIZEMONITORINGOFTHEEFFICIENCY,OFSTOCKS,QUALITY,對效率，庫存和質量的標準華監控IMPROVEDATACOLLECTION;改進數據收集MANAGETHEEQUIPMENTANDTYPECHANGES管理設備，類型改變INTEGRATEDMANAGEMENTOFAUTONOMOUSMAINTENANCEWITHREGARDTOOTHERASPECTSOFTPMANDPURSUITOFCONTINUOUSPERFORMANCEIMPROVEMENTGOALS涉及到TPM其它方面的自主維修的綜合管理，追求，完成不斷改善目標The7stepsofautonomousmaintenance自主維修的7個步驟Timetable時間表Averagetimeofimplementationofthefirst4stepsofAM自主維護的前4步執行的平均時間0-2nd.Step0-2步3rd.Step第3步ModelArea示范區100days100天1year1年3/6months3到6個月Extensionofthe3rd.Steptoalltheplant將第3步擴展到整個工廠內Implemetationof4th.Steponthemodelarea在示范區執行第4步

PreliminaryactivitiesnecessaryforacorrectdefinitionandimplementationofAM:正確定義和執行AM所必需的初步活動：MatrixCofCostdeploymentanalysisandindividualizationoflossesduetobreakdowns.成本部署分析的C矩陣及由損壞造成的損失的特性Machineclassification機器分類.Targetdefinition:eg.Reductionof90%cleaningtimeonthemodelarea,max1breakdownpermonthonmodelarea,zerobreakdownsonthecriticalmachineduetolackofbasicconditions.目標定義：如，示范區有90%的清潔時間減少，每月示范區最多損壞一次，由于基本條件缺乏的重要機器實現零故障。Individualizationofmodelarea.使示范區個性化Teamcomposition.團隊合成PlanningofAMprojects.AM項目的計劃Step0–Preparation步驟0-準備Paintshop噴漆車間CabAssemblyTractorAssemblyDrivelineAssemblyStep0–ModelArea步驟0-示范區Trainingoftheoperatorsofthemodelareadonebythemaintenanceguys“theteamleaderandtheoperatorsmustbecomeownersofthemachine”(explainhowthedeteriorationoccurs,diffusetheknowledgeregardingtheimportanceofsafetyduringAMactivities,developknowledgeonhowthemachineworks)andanalysis/executionoffunctionalschemesofthemachines.由維修人員執行的示范區的操作工的培訓，“小組領導和操作工一定要成為機器的擁有者”（解釋磨損是如何發生的，在自主活動期間，傳播安全重要性方面的知識，開發機器是如何運作方面的知識）并分析或實施對機器有作用的計劃。PredispositionofallnecessarymaterialsforAM(Rags,detergent,paintbrushes,Tags,formatsfordatacollectionetc.)AM中所有必需材料傾向的狀態（碎片，清潔劑，油漆刷，標簽，數據收集的版式等）Step0–ModelArea步驟0-示范區Step0–Preparation步驟0-準備Input輸入MatrixCofCostDeployment成本部署C矩陣Machinesclassification機器分類Output輸出Radarchartoftheteam小組雷達圖Masterplanincludingactivitiesforeachstep,auditsandcorrectiveactionsnecessaryforsolvingthecriticalitiesfoundduringtheaudits總體規劃，包括每一步的活動，審核和處理危險程度所必需的矯正行為，該危險程度是審核過程中發現的。Team團隊-Operators/Maintenancepeople.TheresponsibleoftheteamisthePillarleaderoftheplant操作工/維修人員，團隊中的責任人是工廠內的支柱領導。Tools工具OnePointlessonstodeveloptheskillsoftheoperators開發操作工技能的單點課程Radarchart雷達圖KPI’s關鍵業績指標Know-howachievedbytheoperatorsandmeasuredwiththenumberofOPL’sandwithain-outtestofstep0;由操作工取得的技能并由單點課程數量和步驟零的內外測試進行衡量numberofoperatorsinvolvedinthemodelarea加入示范區的操作工人數Remarks備注OPLonsafetybeforestartingAMactivities開展AM活動前的安全單點課程Fromstep1tostep2foreseeaninvolvementofthePMteaminordertoincreaseandconsolidatetheknowledgeoftheoperatorsregardingtheactivitiesofcleaning,inspection,lubricationandcontrol.為了增加，鞏固操作工在清潔，檢查，上油和控制方面的知識，步驟1到步驟2預知有PM團隊加入。Step1–InitialCleaning步驟1-初步清潔Initialcleaningandinspectioninordertoremovedustanddirtthatarethesourcesofdeteriorationofthemachines.為了除去灰塵和污垢，要進行初步的檢查，此灰塵和污垢是機器磨損的來源。Removedustanddirtofallthepartsofthemachine.除去機器上所有零件上的灰塵和污垢。Hangtagsonthemachineshowingalltheanomalies,sourcesofcontamination,hardaccesszoneswhichcancausequalitydefects.在機器上掛上標簽，展示出可能造成質量缺陷的所有的異物，污染來源，硬的接觸區。Removealluselessobjectsandcreatetidinessandcleanliness.移走所有無用的東西，創造整潔，清潔的環境。Writethelistofanomalies記下異物清單

...CLEANINGISINSPECTING清潔就是檢查MACHINECLEANED清潔的機器DIRTISREMOVED,CHIPS,SCRAPSAREREMOVED除去了污垢，碎片，廢料THEELEMENTSOFTHEMACHINERYARETOUCHEDWEARANDDOWNGRADINGISPREVENTED預防了磨損和降格THEPLANTISKNOWN工廠被大家所知IRREGULARFUNCTIONINGISIDENTIFIED不規則的機能已被鑒定WEARISCHECKED磨損已被檢查PREVENTION預防useman’s5sensesAppropriately適當地使用人的5種感覺Step1–InitialCleaning步驟1-初步清潔Operatorslearnthatcleaningisinspection…操作工學習清潔就是檢查…improvingtheirabilitytotraceminorproblemsandtodiscoverirregularitiesduringcleaning在清潔期間，提高追蹤小問題，發現不整齊東西的能力。AimsofInitialcleaning初步清潔的目標Step1:InitialCleaning步驟1：初步清潔I'llstarttocleanwitharagIhavealsogottoinspecttheinsidetheofmachine

Toomuchgrease!

Thecover’smissing!

Theoillevelisn’tvisible!

Too

muchdirt

andnotenoughgrease

Excessleakageofoil

Thisway,

I’lltraceallthefaults!

ThepressureisOK

Continuoustagging不停的加標簽Indicationofissueoftag指出標簽上的問題Shortcircuitduetosimpleproblems小問題造成的短路Repetitive(chronic)Causesunknown反復出現的（長期的）未知原因Listoftags標簽清單Tagsattached附上的標簽Tagsremoved去掉的標簽Action行動SolvingoftheProblem問題的解決TeamLeader+BTULeader+GroupTeamLeader+BTULeader+Maintenance+Aut.Maint.Resp.Step1:initialcleaning步驟1：初步清潔

Step1–InitialCleaning步驟1-初步清潔Inthisphasetheoperators,afterreceivingthetrainingonsafety,howtoclean,whichtoolstousefortheactivitiesandhowtopayattentioninordernottocreatedamagestothemachine,theycanstarttheinitialcleaning.It’simportanttoremoveallthedirt,findalldefects,anomaliesandhiddenbrokenthingsplacingAMtagswheretheproblemsare.為了不給機器帶來損壞，此階段中的操作工在受到安全，怎樣清洗，活動中使用哪種工具，如何注意培訓后，他們可以開始進行清洗了。除去貼上AM標簽地方的所有污垢，找出所有缺陷，異物和隱藏的損壞東西很重要。BeforeAfterBefore之前After之后

Step1–InitialCleaning步驟1-初步清潔

Step1–InitialCleaning步驟1-初步清潔Output輸出

Listofalltheanomaliesassigningresponsibilitiesanddeadlines.列出所有的異物，指明歸屬責任和截止時間Quantificationofcostbenefitsofthestep量化此步中的成本收益Suggestions建議Hoursoftrainingand/orOPL’s培訓和/或單點課程的時間PlanofAMactivitiesforcleaningAM清潔活動的計劃Team團隊TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.AtthelaunchofthefirstAMactivity,it’srecommendablethattheplantmanagerispresentandactivelyparticipates,tocreateinvolvementandtogivetherightcommitment.此活動中包括了示范區內的所有操作工，由支柱領導指導。第一個AM活動開展時，可以推薦廠長出席并積極參加，呼吁人們參加并給出適當的評論。Tools工具AMtagsmustbeusedplacingthemneartheindividualizedanomaliesorcanbeusedtosuggestanimprovement.AM標簽可被放在個別異物旁或被用于提出改善建議。TheAMtags,usually,areblueifsolvedbyoperatorsandredifsolvedbymaintenancepeople.該AM標簽若是由操作工解決的就是藍色，若是維修人員解決的就是紅色。KPI’s

關鍵業績指標

NumberofAMtagsperweek(considerthatforanaveragecomplexmachine,thenumberoftagsaftertwo/threeweeksofactivitiesofcleaningandinspectioninordertobeconsideredasuccess,itshouldbearound300/400tags.)每周的AM標簽數（對于復雜程度一般的機器，考慮其2到3周的清潔檢查活動后的標簽數量，為了成功，標簽數應為300到400左右。）Implementationrate(Tags)執行比率（標簽）Numberofquickkaizens快速改善數量Savingsontechnicalcleanings技術清潔方面的節省Regardingthecalendar:hrs/week,hrs/weekofovertimeforAMactivities關于記錄表：AM活動超時的時間（小時/周）Remarks備注Organizetheactivitieswithoutinterferencewithproductionorganizingthestoppagesororganizingwhenthemachinesarestopped(nightshift,Saturdays,Sundays)組織停產活動，組織停頓或在機器停止時組織（夜班，周六，周日）Assuremaximuminvolvementofthepeopleontheshopfloor:e.g.Paintingthefloorofthemodelareawhitesothateveryonecan“see”thesourcesofdirtandsothateveryoneunderstandstheresponsibilityofkeepingtheworkplaceclean.確保車間人數最大量的參加：如，將示范區噴為白色，以便大家都能看到污垢來源，并讓大家明白保持工作場所清潔的義務。Godeepintheanalysisofeachcomponenttounderstandthenecessitytolubricateeveninvolvingthevendor.Weareusuallyconvincedthatwhatwelubricateisenoughbutifwegoindetailwefindoutthatthere

ismanyotherthingstolubricate.深入分析每個零件，明白上油的必要性，即便是聯系賣方。通常我們都相信我們所上的油足夠了，但是再仔細看來，還有許多其它東西要上油Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對策Individualizethesourcesofcontaminationandthehardaccesszones.個別加以考慮污染來源和硬的接觸區Findcountermeasuresforthesourcesofcontaminationandthehardaccesszones.找出污染來源和硬接觸區對策。Reducetimeforcleaning,inspectionandlubrication.清潔，檢查和上油的時間減少。Step2–countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對策‘Platecover’Lowcost,easytoapply成本低，易于應用‘Boxtype’Lowcost,veryEffective成本低，很有效Changethematerialtoplastic,rubberorsheetsteel將材料變成塑料制品，橡膠或鋼板Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對策Before之前After之后Installationoftraytocollectchipsandoilfrommachining安裝托盤來收集加工時漏出的碎片和油Contaminationwithchipsandoilfrommachinedparts機械零件上的碎片和油漬污染CleaningTimeReduction清潔時間的減少Machine:COMAUTransferLine Area:GearBox機器：COMAU傳遞線區域：傳動箱Before之前After之后Otherresults:其它結果：CleaningTime(Minutes/day)Problem:difficultaccessduetotheshapeofthecovers問題：由于蓋子的形狀而難以接近Countermeasure:installationofmeshcoverswithsafetydevices對策：安裝安全裝置-網狀蓋子-53%EXAMPLEStep2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對策Extensionto6similartransfermachines延伸至6種類似的轉移機器-Eliminationoffloorslickness消除地板的光滑Step2–Countermeasuresagainstsourcesofcontamination–ActionPlan步驟2-清除污染來源的對策-行動計劃Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對策Step2–Countermeasuresagainstsourcesofcontamination步驟2-清除污染來源的對策Output輸出Listofallthesourcesofcontaminationandcountermeasuresfortheirtheelimination.列出所有的污染來源并找出相應的清除對策Team團隊-TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.該活動包括示范區的所有操作工，且由支柱領導指導。Tools工具-Quickkaizens:PDCAactivitiesofproblemsolving快速改善：解決問題的PDCA活動KPI’s關鍵業績指標Numberofimplementedcountermeasuresindividualized.個別加以考慮的對策的實施數量Cleaningtimereduction清潔時間的減少Lubricationtimereduction.上油時間的減少Inspectiontimereduction.檢查時間的減少Costbenefitanalysisofthestep.此步的成本收益分析Breakdowntrendonthecriticalmachines重要機器的損壞趨勢Remarks備注Inthecostbenefitanalysis,takeinconsiderationalsothereductionofthecleaningtimeofthetechnicalcleaningsexecutedbyexternalcontractors.在成本收益分析中，也考慮由外商執行的技術清潔時間的減少。Calculatealsothesavingscomingfromthereductionofmaterialsandenergydirectlylinkedwiththesourcesofcontamination(eg.Oilecc.)也計算直接聯系到污染來源的材料和能源的減少。（如：油等）Step3–Initialstandards步驟3-初步標準Createinitialstandardsforcleaning,inspection,lubrication,tightenings,visualcontrols,thatallowtheoperationswithlesstimeandefforts(specificatingwhichpartofthemachine,time,frequency,gaugesettingmanagement,assignementoftasksandresponsibilities.為清潔，檢查，上油，固定，可視化控制創建初步標準，用較少的時間和努力進行操作，指明機器的某個部分，時間，頻率，設置管理的標準尺，任務和責任的分配。Improvetheeffectivenessofthestandardsintroducingvisualmanagement.

提高介紹可視化管理標準的有效性。Reducetozeroallbreakdownsduetolackofbasicconditions(lackofAM)ofthecriticalmachines.將由于關鍵機器缺乏基本條件（缺乏自主維修）造成的故障減為零。Problem問題

ONEPOINTLESSON(OPL)單點課程Comp.by:…..Dateoftraining培訓日期Trainer培訓者Pupil學生Improvement改善

Date:15/07/03Basicknowledge基本知識Topic:FLOWMETERS–visualcontrolofoperatingrange話題：流動表-操作范圍的可視化的控制Plant:M.F.O.U.:ENGINESBTU:105OP.110SAIMPGRINDINGaOperatingrangehighlightedwithindicationinred(incorrectoperatingrange)andgreen(correctoperatingrange)用紅色突出不正確的操作范圍，綠色突出正確的操作范圍Signature簽名:INCORRECTOPERATINGRANGE不適當的操作范圍CORRECTOPERATINGRANGE正確的操作范圍No.17exampleStep3–Initialstandards步驟3-初步標準Markmostimportantboltssoastoimmediatelydetect,withaninspection,anyloosening(whentheboltisloosethepaintlineissectioned)標記最重要的螺栓以便立即進行檢查出一切松動（當螺栓松動時，油漆線就會被截成段）Makethemachineseasytoinspect使機器易于檢查Step3:defineinspection,cleaningandlubricationstandards

步驟3：定義檢查，清潔和上油標準Vibration振動Temperature溫度Visualcontrolreducesthetimenecessaryforinspectingerrors可視化控制減少檢查錯誤的必要時間Numberofbelts帶子的數量Wear,dirt,dust磨損，污垢，灰塵Tension張力1.MAKEHIDDENINSPECTIONPOINTSVISIBLE使隱藏的檢查點可視化2. LOCATEINSPECTIONPOINTS ATEYEHEIGHT以視覺高度定位查找檢查點MAKEHIDDENPARTS VISIBLE使隱藏零件可視化Step3:defineinspection,cleaningandlubricationstandards步驟3：定義檢查，清潔和上油標準Improvementofvisualcontrol可視化控制的改善Improveplantvisibilityinordertofacilitatemaintenance:為了便于維修，提高工廠的可視性：Usecolorsandlabels用顏色和標簽Displayfluidlevels顯示液面高度Makebeltandgearmovementsvisible使運輸帶和齒輪運轉可視化Displaytemperatures,operatingranges,flowsofcoolants,etc.顯示出溫度，操作范圍，冷卻液的流動等。BEFORE之前AFTER之后GEARMOTORSARMASBTU6DIFFICULTTOCHECKCORRECTOILLEVELINGEAREDMOTOR很難檢查減速電機中正確的油位FAST,SAFECHECKINGOFCORRECTOILLEVEL對油位的準快速，安全檢查Step3:defineinspection,cleaningandlubricationstandards

步驟3：定義檢查，清潔和上油標準D=DailyW=Weekly(Saturday)M=MonthlyBM=every2monthsSM=every6monthsA=AnnualDEPT.09PAGE1OF2INSTRUC.:MBU1030REV.:00of09.02.96ISSUEDBY:APPR.:AUTONOMOUSMAINTENANCEPLANMACHINE:CL.L.SAIMP-FORRESTTG.3830PROCESS:REDUCT.BOX/SEMISC.RINVIICleaningoftooltrolley清洗工具車Cleaningofareainsidemachine清洗機內地方Cleaningofwatertank清洗水箱Cleaningofpallet清洗托盤Cleaninginsidetoolcribandoutside清洗工具箱內外ReadingscaleaxisX-Y–Z閱讀比例軸XYZReplaceoilfilter+centraloilcartr.ReplaceoilcoolingairfilterFilter,electricalcabinetCheckonreadingscaleChecktach.dyn.brushes,motorsCheckefficientgroundconnectionCheckmotortake-offYaxisCleaninsideelectricalpanelCheckelec.andoverrunlimitswitchesReplacementspindlemotorfiltersINSPECTIONCLEANINGElim.dirtandchipsElim.dirtandchips-EliminatechipsPreventleaks–gen.cleaningAvoidcorrosionPreventmachinestoppagePreventmachinestoppageImprovesuctionAvoidreadingerrorsPreventmachinestoppageSafetySafetyPreventmachinestoppageSafetyMachinesafetyAircompr.suct./pist.Brush-shove.BrushAspireliquidsBrushorsuctiondeviceRagsandliquidDegr.scalew.alcoholReplaceReplaceReplaceVisualEmerypaper.+sprayTesterAmmeterRagsandsolventBlowingandsprayWrench,etc.WWSMWSMSMATMMSMSMSMSMSMSMSMOperat.Operat.CompanyOperat.2oper.Maint.Maint.Maint.Operat.Maint.Maint.Maint.Maint.Maint.Maint.Maint.YESYESYESYESYESYESYESYESYESYESYESYESYESYESYESYES2525-17400(200)(60)(30)(15)(60)(180)(15)(60)(30)(60)(45)WHATWHYHOWWHENWHOM.st.mM.washTimeExampleStep3:defineinspection,cleaningandlubricationstandards步驟3：定義檢查，清潔和上油標準Step3–Initialstandards步驟3-初步標準Output輸出

Autonomousmaintenancestandard/plan.Contains:thenameofthemachine,thecomponentsubdivision,thecleaningstandard,inspectionandlubricationforeachcomponent,themethodsandthetoolstoutilize,thefrequency,theresponsibility,thedailyplan(it’simportantthatthedetailsoftheplanaredailyandnotweeklyandthatontheplanarewrittenonlythebreakdownsthatareduetolackofbasicconditions(lackofAM).自主維修標準/計劃，包含：機器名稱，零件細分，清潔標準，每個零件的檢查和上油，使用方法和工具，頻率，責任，日常計劃（重要的是計劃的細節是日常的不每周的，計劃中僅記下由于基本條件缺乏（自主維修缺乏）造成的故障）Team團隊-TheactivityinvolvesalltheoperatorsoftheModelAreaanditisguidedbythePillarleader.這項活動涉及到示范區所有的操作者并由支柱領導指導。Tools工具-OPL,SOP,AMplan單點課程，標準操作程序，自主維修KPI’s關鍵業績指標

Costbenefitsofthestandards/plan標準/計劃的成本收益Costbenefitsoftheactivitiesdonefromstep0tostep3步驟0到步驟3內執行活動的成本收益Breakdowntrendonthecriticalmachines.關鍵設備上的損壞趨勢Remarks備注Inordertoevaluatethecost/benefitsoftheactivitiesdonefromstep0tostep3it’snecessaryto:為了評估步驟0到3的活動的成本/收益，必須要：Verify,foreachmachineunderAM,theeconomicallossreductionimprovementsignalizedbyCostDeployment;核實每個自主維修下的機器的由成本部署指出的經濟損失減少改善Consolidatethesavingsofthetechnicalcleaningsexecutedbyexternalcontractors;鞏固由外商執行的技術清潔節省Defineandcalculatethehoursofmaintenancemanpowersavedbytransferringthecleaning,inspectionandlubricationstandardstotheoperators;定義并計算人力維修時間，這些時間是將清潔，檢查和上油標準轉移給操作工節省的CalculatethecostsofAMintermsofmanpower,machinestoppages,tools,materialsandtraining;就人力，機器故障，工具，材料和培訓計算自主維修成本SpecificAMmachineclassificationofthemachinesandcomponents(AA,A,B,C),includeintheclassificationthedataregardingbreakdownsduetolackofbasicconditionsthataresignalizedontheAMplan.機器和零件的具體自主維修機器分類(AA,A,B,C)，包括關于由于基本條件缺乏造成的故障的分類數據，這些基本條件是AM指出的。Step4–GeneralInspection步驟4-全面檢查Theobjectiveofthefirstthreestepsistoavoidthedeteriorationofthemachineryandthemaintenanceofthebasicconditions(cleaning,inspectionandlubrication).前三步的目標是為了避免機器磨損和維修基本條件（清潔，檢查和上油）Step4isfundamentalforthetrainingoftheoperatorsonthetechnicalcharacteristicsofthemachines,inordertoincreasetheirabilityofdiscoveringthemalfunctioningsand,withthehelpofthespecialists,elaborateageneral

inspectionplan.Inthisstepthetrainingregardingqualityaspectsofthemachineandoftheproduct,intermsofparametersofthemachinethatcaninfluencethequality,isalsoimportant

.第四步是操作者對機器的技術特性的培訓基礎，為了增加他們發現故障的能力，在專家的幫助下，闡述了一種全面檢查計劃。此步中的關于機器和產品質量方面的培訓也是很重要的，機器參數同樣也影響質量。Step4–Activities(1/2)步驟4-活動(1/2)

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