TotalProductiveMaintenanceOFFICE

辦公室1

ProcessCertificationQCPCRootCause/CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinicActivityTotalProductiveMaintenance

ACEOfficeQualifyingLevel

TPM2

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

3TotalProductiveMaintenanceisanequipmentmanagementstrategythatimprovesequipmentefficiency.全面生產性維護是一種設備管理策略以提高設備效率。Or,inotherwords...Treatingtheequipmentlikeitisyourown!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4TPMKeyConceptTPM的重要概念Leftneglected...EquipmentBreaksDown如果不重視…設備很快就會壞TPM’sfocusistopreventproblemsbeforeequipmentbreaks.TPM的焦點是要在設備出故障以前防止問題出現。Inthepast,maintenancefocused

on

fixingequipmentafteritbroke.過去，維護工作總是集中在設備壞了以后對其進行修理。5TotalProductiveMaintenance

isaNewWayofWorking

全面生產性維護是一種全新的工作方式TPMAttitude:TPM態度：“Weareallresponsibleforourequipment.”“我們所有人對我們的設備負責。”OldAttitude:過去的態度：“Ioperate,youfix.”“我操作，你修理。”“Ifix,youdesign.”“我處理，你設計。”“Idesign,youoperate.”“我設計，你操作。”6Afailureisjustthetipoftheiceberg!HiddenDefects隱藏的問題Failures故障Wear,play,slackness,leakage,dust,dirt,corrosion,deformation,adherenceofrawmaterials,surfacedamage,cracking,overheating,vibration,noise,andotherabnormalities.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。TipoftheIceberg

冰山的頂端7ComponentFailure部件失靈TypicalCausesofEquipmentBreakdown

典型的設備故障原因Failuretoreplacetoner更換墨盒失敗Paperjam卡紙Iwonderwhat’sgoingtofailnext?我想下面還會出什么問題呢？Dirtandcontamination灰塵和污染Outofpaper缺紙8TPMBenefitsTPM的益處Reducedmaintenancecosts減少維護費用Breakdownmaintenanceis10timesmorecostlythanplannedmaintenance故障維修費用是有計劃進行維護費用的10倍以上Enhancedsafety提高安全性Findexposedwires,openbelts,missingguards,loosehardware發現暴露在外的電線、松開的安全帶、缺少防護、松開的部件Reducedwaste減少浪費Preventslossoflubricant,compressedair防止潤滑油、壓縮空氣的浪費Improvedquality提高品質Equipmentmorecapableofholdingtolerance設備抗性增強Lessdowntime,longerlife縮短停工時間，壽命更長9TPMQualifyingCriteria(BusinessProcess/Office)ACEElementAwarenessTrainingforallemployeesEquipmentassessmentA,B&CPMplanfor100%ofcategory“A”equipmentWhat’sAheadBRONZETPMCRITERIAImplementPMPlanTrackdowntimehistoryforvitalmachinesProcessManagementIdentifyKeyProcessesIdentifyWasteEliminationOpportunitiesQualifyingAwareness&Baseline10TPM合格標準

(商業程序/辦公室)ACE內容認知培訓，針對所有員工A,B&C類設備評估所有“A”類設備的PM計劃前面是什么？銅牌TPM標準執行PM計劃追溯重要機器的停工歷史記錄程序管理確定關鍵程序確定浪費消減方法合格認知&基線11SullairSafetyLockout

ProgramProcedure

壽力安全設備鎖定計劃程序LockoutProcedures:鎖定程序：Actionsnecessarytolockoutapowersourceofanymachinetoberepaired,servicedorset-up,whereunexpectedmotion,oranelectricalorotherenergysource,wouldcausepersonalinjuryorequipmentdamage.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引起人身的傷害或設備的損壞。LockoutTag:鎖定標簽12WARNING警告NEVERACCEPTLOCKOUTSKEYSFROMANYONE.決不要從它人處接受鎖定設備的鑰匙。THEASSOCIATERESPONSIBLEFORAPPLYINGTHELOCKORTAGISTHEONLYPERSONAUTHORIZEDTOREMOVETHELOCKORTAG.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/TagoutReview:鎖定/標識檢查13ACTIONITEM1:

AssessAllEquipment

活動內容1：評估所有設備By“Equipment”wemeananymachinethatwasacapitalexpenseandhasadepreciativevalue.Oranymachinethatisimportanttoyourcell.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。WeCategorizeallEquipmentbasedonhowUniqueandCriticalitistoensurewefocusattentionontherightequipmentfirst.Payspecialattentiontobottleneckequipment.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。14?ACTIONITEM1:AssessAllEquipment(cont.)

活動內容1：評估所有設備（待續）CategoryA:

Criticalequipmentforwhichanalternatemachineisnotfeasible,because:A類：不能用其它設備替代的關鍵設備，因為：Noalternateexists,or無替代設備，或Thealternateisusuallyunavailableduetoutilization,or該替代設備通常正被使用而不能獲得，或Itwouldbetoocostly/timeconsumingtotransitiontothealternate太貴/需花太多時間進行替換CategoryC:EquipmentforwhichitisrelativelyeasytofindareplacementoralternateC類：相對容易用其它設備替代的設備Includesmostoff-the-shelfequipment包括最常用的設備Typicallycost<$2,500費用低于$2,500Standardspareparts(likedrivemotors)areavailableoff-the-shelf可獲得的常用標準備件（如驅動馬達）CategoryB:

Allotherequipment/machinesB類：所有其它設備/機器15Inadditiontomachinecategory,createatablelistingallmachinesandadditionalcategories,suchas:

除了機器分類，還應作一表格列出所有機器和附加類別，如：Itemdescription/IDnumber物品描述/ID號Category種類ItemOwner物品主人Identifyequipment’stitleholderanda“local”ownerifappropriate確定設備名義上的擁有者及一“本地”主人，如有必要的話Departmentmanager’ssignature部門經理的簽名ACTIONITEM1:AssessAllEquipment(cont.)

活動內容1：評估所有設備（待續）DepartmentManagerCategoryA/B/CListA/B/C類清單CopierEpsonPrinterAirconditionerPersonalComp.PersonalComp.PersonalComp.PersonalComp.BCACCCCUserNameUserNameUserNameUserNameUserNameUserNameUserNameCo.NameCo.NameCo.NameCo.NameCo.NameCo.NameCo.Name435653217e76544082318921802345

Item物品ID#Category類型TitleHolder名義主人LocalOwner本地主人16Example:OfficeEquipmentAssessment WorksheetTotalProductiveMaintenance,OfficeEquipmentAssessmentWorksheetNote:Evaluationformachineonly.NotfornetworksEquipmentnameDept.EquipmentID#ResponsibleIndividualProductivity1.Howoftenistheequipmentusedeachday? 80%orabove 5 50-80% 3 50%orbelow 22.Istherebackup/alternateequipmentavailable? No(oneofakind) 5 Yes(anotherdept.) 3 Yes(indept) 13.Towhatextentwillafailureofthisequipmentaffectotherofficeprocesses? Stopsentiredept.process 5.Dootherprocessesrunthroughthisequipment? Slowsotherdept.processes 4 Onlyaffectsthismachine 14.Towhatextentwillafailureofthisequipmentaffecton-timedelivery? Decisively 5 Somewhat 2 NotSignificantly 1Quality5.Howwilltheprocessesrunonthisequipmentaffectfinalqualityofthe Decisively 5finishedproduct/service? Somewhat 2 Notsignificantly 1Maintenance6.Whatistheaveragemonthlycostofrepairstothisequipment? $1000ormore 5 $0-$1000 4 ServiceContract 27.Whatistheaveragetimeittakestorepairthisequipment? Over3hours 5(Helpdeskresponse,ifapplicable) 1-3hours 4 0-1hour 2Safety,Environment,Housekeeping8.Dosafetyenhancementsneedtobeapplied?Doestheequipmentneedahousekeepingschedule? Bothanswersare“yes” 5 Oneansweris“yes” 3“A”Machine: 32-40 noneareyes 0“B”Machine: 22-31 MachineCategory: TotalScore:“C”Machine: 21orless 17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-$1000 4

售后服務 27.平均花多少時間修理該設備? 3小時以上 5(Helpdeskresponse,ifapplicable) 1-3小時 4 0-1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

18

ACTIONITEM2:PMPlanon100%“A”

活動內容2：針對所有A類機器的PM計劃OperatorPMdefinedfor100%ofCategoryAmachines.為所有A類機器制定操作員PMDetermineifthereareany“A”machinesinyourarea確定你的工作區域是否有A類機器Ifthereare,theremustbeaPMplan:如果有，應有一個PM計劃：In-house內部OutsideContractor外部合約人Rev:BRevisionDate:3/25/98OperatorPreventiveMaintenanceServiceCardMachine:OkumaLC-30,4Axis,BT#3054DailyPMTasks1.

Checkrunningsight.2.

CheckandfillWaylube:Vactra2.3.

Checktrampoilandscrounger.Emptytrampoilifrequired.4.

Checkandfillcoolant:PML9333.WeeklyPMTasks:DoDailytasksandthefollowing:1.

Checkandfillspindlelube:DTE24.2.

Checkandfillairlubricator:DTE24.(Shutoffanddrainairtofill)3.

Checkmotorfanfilter(Changeifnecessary):Cat.#030058.4.

Checkandfillhydraulictank:DTE24.5.

Checkrollfilter(Changeifneeded):Cat.#027793.MonthlyPMTasks:Doalltasksonthissheet.1.

Greasechuckfittings,1shot.2.

Grease1fitting,2shots,bothturrets.3.

Cleanairfilter.4.

Changeairfilter:Cat.#021183.19

ACTIONITEM2:PMScheduleon50%A&B(cont’d)

活動內容2：針對50%A和B類機器的PM進度表（待續） FollowingishighlyrecommendedtomakeOperatorPM effective:強烈推薦跟進以確保操作員PM的實施：

Usea“Visibleat-a-glance”system(Suchasacolor-codedPMStatusboard)withintheworkareatoindicatetheactualstatusof“OperatorPM”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MustbeeasytounderstandNobookorfoldertoread必須容易理解無需翻書或文件夾20Whatisnext?

下一步是什么？CompleteTPMtrainingofyourworkgroupbyMarch7,20012001年3月7日前你的工作組應完成TPM培訓BeforetheendofFebruary,lookforagroupwiseannouncementofa“Driver’s”Meetingtodiscussthenecessaryresourcesandlogisticsforcompleting