全员生产保养08PTPM08Q3bil.ppt

1、全员生产保养Total Productive Maintenance,目录 Table of Contents,TPM概略 TPM Overview TPM目的 The Aim of TPM TPM流程 TPM Process 自主保养 Autonomous Maintenance 计划保养 Planned Maintenance 预防工程 Preventive Engineering 教育与行动 Education & Practice 保证质量 Insured Quality TPM改善活动 TPM Kaizen Activities TPM活动进阶 Advanced TPM Activi

2、ties,TPM概略TPM Overview,何谓 TPM What is TPM,全员生产保养是这样一个系统 Total Productive Maintenance is a system that 涉及工场 / 维修人员 Involves both shopfloor associates and maintenance associates 支持精益西格玛流程 Supports the LeanSigma Process 保持设备最佳状态 Keeps equipment in optimal condition,为何要实施 TPM Why Implement TPM?,忽视设备基本状况

3、 Basic Equipment conditions neglected 操作维修技能欠佳 Insufficient operating and maintenance skills 设备设计固有不足 Inherent weakness in equipment design 设备恶化无人监督 Overlooked deterioration 没有遵守使用要求 Usage conditions not observed,宏观愿景 Macro Vision,TPM 世界性的公司 World Wide Company,工人自主保养 Operator Autonomous Maintenance,

4、预防保养 Preventive Maintenance,经理支持功能 Manager Support Function,工程设备 设计改善 Eng. Equip. Design Improvement,品质改善 Quality Improvement,全员生产保养 T P M,高级管理层领导 S M L,生产准备 2P,西格玛改善 Sigma Kaizen,TPM目标 TPM Goals,零故障 Zero Breakdowns 零缺陷 Zero Defects 零事故 Zero Accidents 全员参与 Total employee involvement 提高机器效率, 满足节拍速度 A

5、chieve Takt Rate at the highest machine effectiveness,TPM与精益西格玛流程 TPM and LeanSigma Process,精益西格玛 LeanSigma Process,及时 生产 Just in Time,自働化 Jidoka,畅顺生产 Production Smoothing,机器可靠 Machine Reliability 机器高效 Machine Effectiveness 联动操作 Linked Operations 人力利用 Labor Utilization,制程能力 Process Capability 最佳机况 O

6、ptimal machine conditions 制程重复 Process Repeatability 防错装置 Mistake Proofing,实现流畅生产, 必须实行TPM TPM is essential when flow production is achieved,TPM与传统保养 TPM vs. Traditional Maintenance,每班8小时 8 hr shift,有效时间 = 7小时40分 Effectiveness = 7 hrs 40min,工人开会: 10分钟 Operator Meeting,10 min,10 min,设备清洁与润滑: 10分钟 Equ

7、ipment cleaning & Lubrication,传统生产班次 Traditional Operating Shift :,实行TPM的班次 TPM Shift :,本班开始 Shift Start,品质问题 Quality,暂停 Minor Stoppages,故障停机 Breakdown,调整 Adjustment,本班结束 Shift End,每班8小时 8 hr shift,有效时间 = 6小时 Effectiveness = 6 hrs,量度指标 Metrics,整体设备效率 Overall Equipment Effectiveness (OEE) 可用效率 Availa

8、bility 性能效率 Performance 品质效率 Quality,保养效率 Maintenance Effectiveness 平均故障时间间隔 MTTF (Mean time to failure) 平均无故障时间 MTBF (Mean time between failure) 平均维修时间 MTTR (Mean time to repair),TPM的目的：The Aim of TPM :,改善设备运行状况 To improve the equipment operating condition 维持设备最佳性能与可靠性 To sustain equipment at an op

9、timal level of performance & reliability 延长设备使用寿命 To lengthen the life expectancy of equipment,TPM流程TPM Process,TPM五大支柱 The 5 Pillars of TPM,自主保养 Autonomous Maintenance,计划保养 Planning Maintenance,预防工程 Preventive Engineering,品质 Quality,教育与行动 Education & Practice,实施TPM十步骤 TPM Implementation -10 Steps,1

10、.测量工作单元上所有自动设备之OEE Measure OEE for all automatic equipment in cells. 2.测量各工作单元的节拍时间 Measure Takt rate performance for each area. 3.将单元节拍时间与设备OEE进行比较 Correlate cell takt rate performance to equipment OEE. 4.选择特定机器作为改善重点 Select specific machine for kaizen focus. 5.根据OEE六大损失制定改善目标 Establish improvement

11、 goal related to the six major losses of OEE. 6.选定设备改善专职队员 Select permanent equipment improvement team members. 7.发动工人进行自主保养及计划保养活动 Initiate operator autonomous maintenance and planned maintenance programs. 8.继续更新检查单, 培训工人, 保证机器最佳状况 Continue to update check lists, train operators, and pursue optimal

12、 machine conditions. 9.为选定设备设立TPM活动之目视表现板 Establish visual performance boards for TPM activities on selected equipment. 10.每月将改善目标与实际结果进行比较。评价是否需要进行更多改善活动, 制定更高的目标, 或需要更换专职队员 Check results to improvement goals monthly. Evaluate need for additional kaizen activity, setting more aggressive goals, or m

13、odifying permanent team members.,自主保养Autonomous Maintenance,自主保养 Autonomous Maintenance,工人要学习 A system where equipment operators learn to : 进行每日检查 Perform daily checks 按需润滑设备 Lubricate equipment as needed 更换简单零件 Replace simple components 进行机器小修 Perform minor repairs on machines 帮助解决问题 Assist in prob

14、lem solving,工人是机器发生异常的早期预警系统 Operators become the early warning system for machine abnormalities,自主保养五步法 5 Steps to Autonomous Maintenance,1.进行基本清洁活动 Perform basic cleaning 2.根除肮脏污染源头 Eliminate sources of dirt and contamination 3.建立清洁润滑标准 Establish cleaning and lubrication standards 4.教会设备基本检查, 进行自主

15、设备检查 Teach general inspection of equipment and Perform autonomous equipment inspection 5.培养整齐有序习惯 Instill orderliness and organization,工人作用 Roles of Operators,预防污染 Prevent deterioration : 维持基本条件 Maintaining basic conditions 正确操作设备 Operating equipment correctly 判断污染 Measure deterioration : 进行检查 Inspe

16、cting 制定标准, 坚持执行 Developing and adhering to standards,纠正污染 Correct deterioration : 报告问题 Reporting problems 协助维修 Assisting in repairs 进行微调 (按本地合约) Making minor adjustments (per local contract) 加入团队 Participate in teams : 工作中心团队 Work center teams 解决问题团队 Problem-solving teams,维修人员作用 Roles of Maintenanc

17、e Personnel,设备保养 Maintain Equipment 检验 (拆卸) Inspect (disassembly) 计划保养 Planned overhauls 预防保养 Preventive maintenance 教导工人学会特定保养工作 Teach selected maintenance tasks to operators,设备改善 Improve Equipment 支持可靠性及可维修性改善 Support R&M improvement 实施预测技术 Implement predictive technologies 纠正设计不足 Correct design w

18、eaknesses 搞好供方合作 Partner with vendors,设备检查表 Equipment Inspection Checklist,初步清洁 Initial Cleaning 螺母、螺栓等有无松动、摇摆、遗失? Any nuts, bolts, etc. loose, wobbly or missing? 活动零件、夹具安装有无窜动? Any play in moving parts or fixture mounting section? 机器内部有无多余零件? Any unnecessary items located on the body of the machine

19、? 润滑系统 Lubrication 润滑油是否到达滑动部件? Does oil reach sliding parts? 润脂嘴、机油盖等是否损坏、遗失? Any damaged or missing grease nipples, oil caps, etc.? 供油装置、管路、接头有无漏油? Any oil or grease leaks from supply devices, pipes, fittings? 加油工人有无内外清洁? Are oilers clean inside or out? 油标是否容易看见? Is the oil level easily visible?,设

20、备检查表 Equipment Inspection Checklist,液压系统 Hydraulics 油箱装够油了吗? Is the oil tank filled to the specified level? 油泵发出异常噪音吗? Is the pump emitting any abnormal noises? 卸荷阀、减压阀、节流阀防松螺母上紧了吗? Are locknuts tight on relief, reducing and throttle valves? 卸荷阀、控制装置运作正常吗? Are relief valves and controls operating co

21、rrectly? 高压管路连接变形或磨损了吗? Any strain or wear in high pressure hose connections? 电器系统 Electrical 行程开关杠杆能够完全接触吗? Do limit switch bars strike fully? 信号灯、指示灯遗失或烧坏了吗? Any missing or burned out pilot or indicator lights? 配电盘、电器箱有无线路图? Are there wiring diagrams in the control panels or electrical boxes? 有无多余

22、的、损坏的、压坏的电线或软管? Any unnecessary, damaged or dented wires or flexible tubing?,设备检查表 Equipment Inspection Checklist,传动系统 Power Transfer Devices V型皮带碰到带轮槽底了吗? Do V-belts hit the bottom of pulley grooves? 皮带有无损坏、爆裂、破裂? Any damage, cracking or splitting of the belts? 滚柱链条的销轴与轴承之间有无足够润滑油? Is there suffici

23、ent lubrication between pins and bushings of roller chains? 转轴有无过热、振动、噪音? Any shaft overheating, vibration or noise? 联接系统有无锁键、夹紧螺栓松动造成的窜动? Any play due to loose keys or clamping bolts on couplings? 齿轮机构有无过量的躁音、发热、振动? Any excess noise, heat or vibration in gear mechanisms?,设备检查表 Equipment Inspection

24、Checklist,螺母螺栓 Nuts and Bolts 登记记号允许松紧度检查吗? Do registration marks permit tightness checks? 螺母螺栓型号及尺寸正确吗? Are nuts and bolts of the suitable types or sizes used? 垫片尺寸正确, 且类型相配吗? Are washers of proper size, and are they consistently used? 螺栓有从螺母凸出23圈螺纹吗? Do bolts protrude 2 3 threads from the nuts? 气动

25、系统 Pneumatics 截止阀及球阀漏气吗? Any stop valve, ball valve leaks? 有坏了或多余的手把吗? Any broken or unnecessary handles? 已关闭的阀仍有气流吗? Does any air flow through closed valves? 有任何不必要的装置或喉管吗? Are any unnecessary devices, hoses or pipes present? 所有喉管都整齐及易于识别吗? Are pipes and hoses orderly and readily identifiable? 压力表指

26、示的都是正确设定的压力吗? Do pressure gauges clearly indicate the correct set pressure?,进行基本清洁 Perform Basic Cleaning,做好清洁检查 Clean to inspect 暴露隐藏不足 Expose hidden defects 找出脏污源头 Determine source of contamination 识别难于清洁之处 Identify hard to reach areas 准备蓝色标签工作 Prepare for blue tag exercise,消灭脏污源头 Eliminate Source

27、s Of Dirt & Contamination,脏污原因 Causes of Contamination: 发生液体泄漏 Fluid leaks 碎片容器很差 Poor chip containment 工作不佳 Poor 5S practices 工作区有溅洒 Work area spills 过滤性能不好 Poor filtration 没有清洁标准 No cleaning standards 无工作自豪感 Poor work pride 环境问题恶劣 Environment,建立清洁与润滑标准Establish Cleaning & Lubrication Standards,从工人

28、开始进行基本的清洁、检查及润滑活动 Begin basic operator cleaning, inspecting and lubricating activities 制定临时标准 Establish provisional standards 进行重点训示 Create one point lesson 确定活动频次 Establish frequency of activities 月检、周检、日检清单 Monthly, weekly and daily check list 制做检查表 Develop check list,重点训示 One-Point Lesson,1.0 目的/

29、范围: 根据3600路线检查单脂具体检查步骤制定详细的工作指示,2.0 责任: 工人,3.0 安全: 标准的工人保护设备: 防护眼镜, 听觉保护用具, 手套, 钢头鞋,4.0 工作指示,第1步: 本工作指示用于与3600路线检查单有关的工作,第2步: 本工作指示用于3600吨冲压机周围的检查工作35,第3步: 检查模具加热炉温度及设定值。绝对最低设定值应为800度,进行自主保养检查Perform Autonomous Maintenance Inspection,制定详细的培训计划 Develop in depth training program 对工人就以下内容进行培训： Train op

30、erators in: 润滑作用/粘性分析 Lubrication/ Viscosity Analysis 气动系统 Pneumatics 液压系统 Hydraulic 电气系统 Electrical systems 驱动系统 Drive systems 修改目前的重点训示, 加入检验检查工作 Revise existing one-point lessons to include inspection checks,灌输工场整洁条理思想Instill Orderliness & Organization,工场管理与控制 Workplace management & control 扩展团队活

31、动, 做好设备以外的整洁工作 Expand team activities beyond equipment to other aspects of the process 搞好工场整洁, 实行目视控制，发现改善机会 (第4、5个S) Expose opportunities for improved organization, orderliness and visual control (4th & 5th S) 进行5S评审 Perform 5S audits,整洁与条理 Organization & Orderliness,目视控制 Visual Controls,写出已做的活动, 展

32、示取得的进步 Describes activities undertaken and shows progress 对比制定的标准, 量化取得的改善 故障停机、维修呼叫、停线时间等 Quantifies the improvements made against agreed metrics. e.g. (Breakdowns, defects, maintenance call-outs, line down-time, etc.) 细化实际的改善 Details the actual improvements made 记录待研究项目 Records issues to be review

33、ed: 没有答复的问题 Unanswered questions 需要支援的问题 Complex issues support required,问题公报 Problem Newspaper,问题公报 Problem Newspaper,生产保养完成率 PM Completion Ratio,保养小组目视控制Maintenance Group Visual Control,活动布告板 Activity Board,自主保养,全员生产保养活动TPM Activities,进行TPM基础知识培训，评审准备工作 Train in TPM fundamentals & Review Pre-work,

34、实施蓝色标签方法 Conduct Blue Tag Exercise 异常情况排序 Rank abnormalities 异常情况维修 Repair abnormalities,设备OEM手册评审 Review equipment OEM manuals 确定工人自主保养路线, 制定检查表 Create Op. AM route & Check sheet,定义 / 实施标准化工作 Define & Implement Std Work 实现保养反馈循环 Implement feedback loop to maintenance 进行OEE表现公告 Implement OEE perform

35、ance board,初步活动 自主保养 Initial Events Autonomous Maintenance,TPM的活动 TPM Activities,改善前活动 (专职队员) Pre-Kaizen Activity (Permanent Team),收集改善活动一个月前的停机数据 Collect downtime data for one month prior to event 进行设备基本清洁活动 Conduct initial cleaning of equipment 收集设备规格、OEM手册、机器BOM及图纸 Gather machine specifications,

36、OEM manuals, machine BOM, blueprints,改善活动 (改善团队成员) Kaizen Activity (Kaizen Team),进行两小时的观察 Conduct two-hour observation 清洁脏污源头, 贴上蓝色标签 Clean and Blue Tag sources of dirt and contamination 集思广益 按实施难易程度排序 Brainstorm ideas Prioritize according to implementation ease 实施解决方案, 消除脏污源头 Implement solutions to

37、 eliminate sources of contamination 设计工人自主保养路线、检查表及重点训示, 实现保养标准化 Standardize and develop Operator Autonomous Maintenance Routes, Check Sheets and One-point lesson 实行OEE表现公告制度 Implement OEE performance board 实施设备保养反馈循环 Implement equipment maintenance feedback loop,清洁检查 Clean To Inspect,改善前 Before改善后

38、After,蓝色标签流程 Blue Tag Process,识别脏污及异常源头 Identify sources of contamination and malfunctions 每个源头贴上蓝色标签 Write a blue tag for each identified item 在机器上靠近源头处挂上蓝色标签 Attach blue tag to machine at location of specific item 在总表上记录蓝色标签资料 Document Tag Information on Summary Chart 与保养人员评审蓝色标签, 按影响程度及修理难易程度排序 R

39、eview tags with maintenance personnel as a team & rank according to impact & difficulty of repair 改善活动期间没有解决的异常问题, 保养人员要做好行动计划, 列明负责人及时间要求 Maintenance completes Who and When information for abnormalities not repaired during kaizen event and creates Action Plan 改善小组更新总表状态 Team updates status of summa

40、ry chart 在每月改善评审会议上, 专职队员评审总表状态 Permanent team reviews status of summary chart at monthly kaizen review meeting,蓝色标签 Blue Tag,蓝色标签,蓝色标签,第1部分,第2部分,编号,编号,日期,日期,检查人,检查人,班次,班次,问题,问题,电气,机械,润滑,操作,仪器 / 控制机构,设备,其它,问题简述,电气,机械,润滑,操作,设备,仪器 / 控制机构,其它,问题简述, 继续见背面,问题可能影响,可使用时间,性能/速度,成品质量,环境,浪费,成本,安全,其它,改正行动计划,执行人

41、,执行人,执行人,日期,日期,日期,工作单号,根本原因 / 行动, 更多见背面,完成日期,位置 / 系统 / 设备 / 零件代号,不足之处, 贴上标签 Deficiencies Tagged,蓝色标签总表 Blue Tag Summary Chart,机器名称 Machine Name : Okuma LC20 B-344,影响程度 /修理难易程度分级Impact / Difficulty Rating,目的 Used To: 发现所有浪费迹象, 提出可能解决方案 Capture waste information and potential solutions 按问题清晰程度及实施难易程度,

42、 将解决方案进行排序 Rate / rank the solutions in regards to resolution of the issues and ease of implementation,标签排序矩阵图 Tag Prioritization Matrix,制程: 通讯技术支持呼叫流程,障碍/浪费,根本原因,解决方案/影响,难易程度,影响,呼叫处理,计算机系统培训,无法快速得到参考资料,无法使用Impromptu,一对一培训,内部培训,没有工作标准,太多排队,无法监视和管理排队,零件处理,喜龙现场人员为非工作事务呼叫技术支持部门,仓存资料不准确,没有零件代号指引, 太多不同零件

43、,零件跟踪程序太过称长 要使用RMA跟踪方法,亲访贝茨维尔 , 与技术支持人员一起工作,开发快速参考模块,让技术人员能使用Impromptu,制定工作标准,改5个队为3个队,使用ACD监视器, 更好管理排队,教育现场人员, 只能为工作事务呼叫技术支持部门,为没有零件代号的产品设计零件代号,开发零件库, 便于快速查找零件,更新Fisher-Berkley零件仓存数据库,为FBB零件供应商Fawn安装网络打印机,为便于零件订购, 安装被喜龙及Fawn共享的订单处理数据库,实现零件代号标准化, 让供应商与喜龙都使用相同的零件代号,影响 /解决的难易程度矩阵图 Impact/Difficulty Matrix,解决的难易程度,影响,自主保养检查表 AM Check List,自主保养检查表,90吨冲床,日 一 二 三 四 五 六,项目说明,工人日检,工人周检,日 一 二 三 四 五 六,日期 备注: 说明潜在问题,员工 班次,检查光帘安装正确与否, 如不正确, 则停机, 立即通知维修人员,调整冲压机, 确保在上冲程尽头而不是经过上感应器时停机,检查有无漏气,检查液压系统有无泄漏,检查油泵有无过大躁音,检查液压系统出口油温,保养所有油脂加油嘴, 检查有无明显磨