全面生产保养TPM.ppt

,全面生產保養,TotalProductiveMaintenance(TPM),全面生產保養介紹TPMIntroduction全面生產保養內容TPMConcepts全面生產保養階段StagesofTPM自主保養層次LevelsofAutonomousMaintenance設備總和效率OEE安全與全面生產保養SafetymaintainandbuildourabilitytocontributetoSafety,QualityandProductivity.保持設備使用壽命最大化。Maintainourequipmentformaximumlifeutilization.提高員工技能，培養員工的專有經驗。Promoteemployeeskillbuildingandimprovetheexpertiseofallemployeesduringthis.,TPMPolicy,TPM的方針,總體效率(盈利能力)TotalEffectiveness(profitability)全面系統TotalSystem&TotalProcess全面參與TotalParticipationofallTeamMembers,全面的定義,TotalDefined,使零停機成為現實Makingzerobreakdownareality消除浪費源Preventinglossesattheirsource提高操作技能，增加機器的性能Raisingskillsandmachineperformance,TPM中操作者的任務,TheoperatorsroleinTPM,設備問題直接影響到操作者的工作Equipmentproblemsaffectoperatorsworkdirectly每個人包括操作者，維修人員、工程師等等都應該盡自己所能去防止設備問題和浪費的發生Everyone(operators,maintenance,engineers,etc.)mustsharewhattheyknowtopreventequipmentproblemsandlosses,讓我們一起行動起來防止浪費,Letsworktogethertopreventlosses!,停機時間DownTime1.設備故障Equipmentfailure-frombreakdowns2.整備和調整Setup&adjustment-fromexchangeofdieinmoldingmachine,etc.速度浪費Speedlosses3.空轉和短時間停機Idlingandminorstoppages-duetotheabnormaloperationofsensors,blockageofworkonconveyors,etc.4.減速Reducespeed-duetoabnormalequipmentoperation缺陷Defect5.製程缺陷Processdefects-duetoscrapsandqualitydefectstoberepaired6.產出減少Reducedyield-frommachinestartuptostableproduction,六大浪費,6BigLosses,有效浪費Availabilitylosses1.停機/次品breakdowns/failures2.安裝/切換setups/changeovers表現浪費Performancelosses1.小的停滯minorstoppages2.減慢速度reducedspeed質量浪費Qualitylosses1.次品和返工defectsandrework2.啟動和產量浪費startupandyieldloss,六大浪費的理解,UnderstandingtheSixBigLosses,收集浪費數據，決定哪種是最嚴重的？Collectlossdataanddeterminewhichlossisthebiggest.,哪種浪費最大Whichlossisthebiggest?,注意並改良小問題，阻止大問題Watchforandcorrectsmallproblems.Preventbigproblems.,請注意細小的問題Payattentiontothelittleproblems!,修改設備或作設計改善之前先要改良快速惡化Correctaccelerateddeteriorationbeforemodifyingequipmentormakingdesign,改善始於復原Improvementbeginswithrestoration,故障排除往往沒有解決真因Troubleshootingoftendoesntsolvetherealcausesofproblems反覆地問“為什麼”可以找到真因，採取預防措施Asking”Why”repeatedlyhelpsuncovertherootcausessowecanprevent,為什麼要問“為什麼”？Whyask“Why”?,兩種類型的浪費Twotypesoffailures:功能喪失functionloss功能減少functionreduction在功能減少時，機器雖然在進行，但是會產生生產延誤和出現次品Inreducedfunction,themachinekeepsrunning,andmayproducedelaysandwastefuldefects,減少功能也是一種浪費Reducedfunctionisalosstoo!,大多數的故障可以追溯到我們可以控制的事件上，例如:Mostfailuretracebacktothingswecancontrol,forexample:誤操作miss-operation缺乏保養lackofmaintenance疏忽退化neglecteddeterioration,機器為什麼會出現故障Whydomachinesfail?,初期故障時期(設計錯誤)Initialbreakdownperiod(DesignErrors)隨機故障時期Randomfailureperiod(AccidentalBreakdowns)磨損相關的故障時期Wear-relatedbreakdownperiod,故障發生的時間Whendobreakdownshappen?,自然老化Naturaldeterioration加速老化Accelerateddeterioration,兩種類型的老化Twotypesofdeterioration,接受新的思維方法Adoptanewwayofthinking做到每日的常規點檢使設備總是處於最好的運行狀態Developadailyroutineforkeepingequipmentintopoperationcondition監視輕微的異常現象Watchforslightabnormalities,我們的任務是預防停機Ourroleinpreventingbreakdowns,可以通過下面的方法來建立和保養基本的設備狀況Establishandmaintainbaselineconditionsfortheequipmentthrough:每天的常規點檢dailychecks復原惡化的狀況restoringdeterioration追查根本原因pursuingrootcauses,保養基本條件Maintainbasicconditions,習慣基本的作業清掃、潤滑、鎖緊螺栓Providethebasics-clean,Lubricate,Tightenbolts堅持相關標準Sticktotherules復原老化Restoredeterioration提高操作和維修機器的技巧Raiseskillsforoperatingandmaintainingmachines,零件機活動Zero-breakdownActivities,整體點檢Generalinspection要求所有生產、工程，以及保養人員都要明白設備的工作原理和我們應當點檢和保養什麼Production,engineering,andmaintenancepersonneljoinforcestounderstandhowequipmentworksandwhatweneedtoinspectandmaintain,了解有關設備系統的知識Learningaboutequipmentsystems,異常點定位Learntospotabnormalities修理和復原Repairandrestore設定點檢的標準Setcriteriaforinspection知道正確的操作程序Knowproperoperatingprocedures追查問題的根本原因並阻止其發生Trackdownrootcausesandpreventthem,如何才不會損傷機器Hownottobreakequipment,喪失標準功能Lossofstandardfunction較長時間的設置調整Longersetupadjustment經常閒置FrequentIdling短暫停機Minorstoppages較慢的加工速度Lowerprocessingspeed可操作時間較少Reducedavailabletime,設備失效EquipmentFailures,可視控制可以幫助控制設備的狀況Visualcontrolshelpcontrolequipmentconditions,建立可視的設備控制Establishvisualequipmentcontrols,通過消除數大浪費來提高設備效率(團隊完成)Improvingequipmenteffectivenessthrougheliminationoftheseveralbiglosses(carriedoutbyprojectteams).建立保養小團隊(遵循六sigma概念法)Establishingateammemberimprovementprogram(followingasixsigmaconceptmethod).品質保證Qualityassurance.保養部門制定保養計劃Establishingascheduleforplannedmaintenancebythemaintenancedepartment.通過教育訓練提高工作技能Educationandtraining,5個基本的改善領域5BasicImprovementAreas,保養良好規範的基本條件Maintainingwell-regulatedbasicconditions(cleaning,lubricating,andbolttightening)遵循適用的操作程序Adheringtoproperoperatingprocedures復原環舊設備Restoringdeterioration明確和改進設計問題Identifyingandimprovingweaknessindesign提高操作和保養技能Improvingoperationandmaintenanceskills,五大對策5Countermeasures,誰的職責？WhoisResponsible?,TPM的準備階段(步驟1步驟6)PreparatoryStageofTPM(Step1-Step6)TPM的實施階段(步驟7步驟12)ImplementationStageofTPM(Step7-Step12),全面生產保養階段StagesofTPM,步驟1:在組織中啟動導入TPM的培訓普及運動Step1:LaunchanEducationalCampaigntoIntroduceTPMtotheOrganization步驟2:建立推動TPM的組織機構Step2:CreateanOrganizationalStructuretoPromoteTPM步驟3:宣布高層管理者的決定導入TPMStep3:AnnounceUpperManagementsDecisiontoIntroduceTPM,TPM的準備階段(步驟1步驟3)PreparatoryStageofTPM(Step1-Step3),步驟4:設定基本的TPM方針和目標Step4:EstablishBasicTPMPoliciesandGoals步驟5:規劃實施TPM的總體計劃Step5:FormaMasterPlanforImplementingTPM步驟6:正式開始TPMStep6:KickOffTPM,TPM的準備階段(步驟4步驟6)PreparatoryStageofTPM(Step4-Step6),步驟7:提高設備關鍵部份的效率Step7:ImprovetheEffectivenessofEachCriticalPieceofEquipment步驟8:建立和實施自主保養保養Step8:SetUpandImplementAutonomousMaintenance步驟9:在保養部門建立計劃保養系統Step9:EstablishaPlannedMaintenanceSystemintheMaintenanceDepartment,TPM的準備階段(步驟7步驟9)PreparatoryStageofTPM(Step7-Step9),步驟10:提供提升操作和保養人員的技能培訓Step10:ProvideTrainingtoImproveOperatorandMaintenanceSkills步驟11:建立設備初期管理制度Step11:DevelopanEarlyEquipmentManagementProgram步驟12:完善TPM並提升TPM水準Step12:PerfectTPMImplementationandRaiseTPMLevels,TPM的準備階段(步驟10步驟12)PreparatoryStageofTPM(Step10-Step12),小組結構應該同總目標保持一致Teamstructurekeepsintouchwithoverallgoals小組中不同層次的成員要增加交流Overlappingmembershipbetweenlevels,為什麼TPM活動小組是很重要的？WhyTPMteamsareimportant?,朝著公司和工廠的宏觀目標工作Worktowardcompanyorplantwidegoals消除浪費意味著質量、成本、交期Eliminatinglossesmeansquality,cost,anddelivery改善我們工作環境的質量Weimprovethequalityoftheworkenvironment,小組活動的目標Goalsofteamactivities,由管理部門或小組選舉Chosenbymanagementorbytheteam需要有設備的專業知識和領導能力Needsfacilitationandleadershipskills使成員都能意識到他們的目標並且知道如何發揮他們的才能Keepteammembersawareoftheirgoalsandhowtheycancontribute,小組組長Theteamleader,參加並提出建議Participateandshareyourideas完成個人的任務Carryoutindividualtasks學習改善活動必須的新技術Learnnewtechniquesneedsforimprovementactivities與其它成員愉快的合作Cooperateandhavefuntogether,小組成員的任務Rolesofteammembers,批准有利於實現公司目標的項目Agreeonaprojectthatservescompanygoals設立清晰的目標:什麼(目標)/時間(持續時間)/如何實現(目標)Setcleartargets:What(objectives)/When(Duration)/How(targets),選擇項目並設立恆定目標Chooseaprojectandsetfirmobjectives,回顧取得的進步Reviewprogress給予資源和鼓勵的支持Supportwithresourcesandencouragement指導朝著公司的目標努力Guideeffortstoalignwithcompanygoals,管理者的角色Managementsrole,顯示團隊的經歷Tellteamsstory“硬”數據“Hard”data“軟”數據“Soft”data,使用活動看板UsingActivityBoards,計劃Plan文件化Document週而復始Circulate,有實效的會議ProductiveMeetings,互相學習:使用方法/必要的經驗/挖掘問題/解決方案Mutuallearningabout:Methodsused/Know-howrequired/Problemsencountered/Solutionsdeveloped,公開結果Publicizeresults,簡單的目視培訓工具Easyvisualtrainingtool十分鐘的專題討論Singletopic-10minutes三種類型:基本經驗/問題實例分析/改善結果Threekinds:basiclesson/Problemcasestudy/Improvement,單一重點課程OnePointLessons,八大策略Eightstrategies注重改善focusedimprovements自主autonomous保養maintenance計劃保養plannedmaintenance技術培訓technicaltraining初始化管理initialmanagement質量保養qualitymaintenance辦公室的TPMofficeTPM環境和安全的管理environmentalandsafetymanagement,立刻行動，開始TPM！ItstimeforTPM!,什麼是自主保養？Whatisautonomousmaintenance?為什麼要作自主保養？Whydoautonomousmaintenance?自主保養保養的七個層次Thesevenlevelsofautonomousmaintenance,自主保養層次LevelsofAutonomousMaintenance,每天系統的點檢活動要成為每個操作員工作的一部分，因為這可以減少非計劃停機時間Systematic,dailyactivitiestopreventunplannedbreakdownsbecomepartofanoperatorsjob,自主保養Autonomousmaintenance,自主獨立AutonomousIndependent操作員進行常規的清潔、點檢和潤滑可以幫助阻止故障發生Routinecleaning,checking,andlubricationbyoperatorstohelppreventbreakdowns必須一步步做到系統化Asystematicstep-by-stepapproach,什麼是自主保養Whatisautonomousmaintenance?,增進設備知識和預防意識Developequipmentknowledgeandpartnerinprevention為持續改進建立基礎Buildafoundationforcontinuousimprovement使工作變得簡單和滿意，提高工作生活質量Makeworkandwork-lifeeasierandmoresatisfying,為什麼要作自主保養？Whydoautonomousmaintenance?,1.初期清掃操作者意識到清掃就是點檢Initialcleaning-operatorslearncleaningisinspection2.髒、亂的因果對策分析Countermeasuresforthecause&effectofdirdust3.制定清掃和潤滑的標準Developmentofcleaningandlubricationstandards4.整體點檢Generalinspection5.自主點檢Autonomousinspection6.標準化Processdiscipline7.徹底實現TPMFullimplementationoftopproductivemaintenance,為什麼要作自主保養？Whydoautonomousmaintenance?,清掃就是點檢Cleaningisinspection點檢意味著發現問題Inspectingmeansfindingproblems儘快標明、解決問題ProblemsaretaggedandcorrectedASAP,層次1:清掃和點檢Level1:Cleanandinspect,在源頭停止問題擴散Stopcontaminationatthesource使問題最小化Minimizecontamination調整設備使得清潔和潤滑更容易Modifyequipmenttomakecleaningandlubricationeasier利用點檢視窗使得點檢更容易Useinspectionwindowstomakecheckingeasier,層次2:消除問題源和消除死角Level2:Eliminateproblemsourcesandinaccessibleareas,清掃、點檢和潤滑設備的人應該為這些工作準備工作標準Thepeoplewhoclean,inspect,andlubricateequipmentshouldpreparethestandardsforthatwork,層次3:建立清掃和潤滑的標準Level3:Drawupcleaningandlubricationstandards,從維修和工程方面了解設備系統Learnaboutequipmentsystemsfrommaintenanceandengineering提高點檢和發現故障並排除故障的技能Developinspectionandtroubleshootingskills,層次4:指導進行整體點檢Level4:Conductgeneralinspections,使維修工作合理化，在生產和維修中間進行適當的分配Streamlinethemaintenanceworkanddivideitappropriatelybetweenproductionandmaintenance,層次5:協調活動Level5:Coordinateactivities,標準化生產過程中的各個方面Standardizeallaspectsoftheproductionprocess優化你的目視管理並且同保養一樣應用於生產中Refineyourvisualcontrolsandapplythemtoproductionaswellasmaintenance,層次6和7:標準化和持續改進Level6and7:Standardizeandcontinuetoimprove,回顧小組的成績Areviewoftheteamsachievement不是測試，只是一個學習的機會Notatest,butalearningopportunity你的成績認可Recognitionofyouraccomplishments,自主保養關鍵:監控過程AMKeys:Monitorprogress,點檢時發現問題就貼上標籤，可以使問題突出化Tagequipmentproblemsnoticedduringinspectiontomakethemvisible解決問題然後拆除標籤Correctproblems,themremovetags,自主保養關鍵:取下標籤AMKeys:Removetags!,停機時間Downtimeduetomachinebreakdown設置和調整時間Timerequiredforsetupandadjustments開機失效時間Timeorcycleslosttoinefficientstartup工裝失效時間Timeorcycleslosttotooling短暫停機時間Timeorcycleslosttominorstoppages低於正常速度度操作Operatingatlessthanidealspeed生產出不合格或超差產品，需要返工、返修，或折價銷售Producingdefectiveoroff-specproductthatisrejected,requiresreworkorrepair,orissoldatalowerprice.,衡量跟蹤七種設備浪費Seventypesofequipmentlossaretracked,總設備效率使用率人工效率合格品率,OEEAvailabilityPerformanceefficiencyQualityrate,使用率有時也被稱為開機率或機器稼動率；其中：Availabilityissometimesreferredtoasuptimeormachineutilization:淨有效時間總有效時間計劃停機時間OperatingtimeTotalavailabletimePlanneddowntime計劃停機時間休息5S集合預防保養培訓PlanneddowntimeBreaks5SPlannedmeetingPreventivemaintenanceTraining,使用率作業時間淨有效時間AvailabilityOperatingtimeNetavailabletime,人工效率有時也被稱為產出效率或機器效率。它反映了機器在生產單個產品時是否滿負荷或全速生產。Performanceefficiencyissometimesreferredtoasthroughputefficiencyorequipmentperformanceefficiency.ItreflectswhetherequipmentisrunningAtitsfullcapacityorspeedforindividualproducts.,人工效率(標準週期時間總生產數量)作業時間Performanceefficiency(IdealcycletimeTotalpartsrun)Operatingtime,合格品率有時稱為產出效率或首次運行能力；其中：Qualityratesometimesreferredtoasthroughputefficiencyorfirstruncapability.,合格品率(總生產數量總次品數量)總生產數量Qualityrate(TotalpartsrunTotaldefects)Totalpartsrun,總生產數量合格品拒收品返工品TotalpartsrunGoodpartsRejectedpartsReworkedparts,總次品數量拒收品返工品報廢品退貨TotaldefectsRejectsReworksScrapShipbacks,假設有一工廠某生產線一天作業時間為8小時，其中用餐、休息時間為1小時，每天在上線和收工之前的開會、點檢、清掃需費時30分鐘，一天中因突發故障而停機時間為20分鐘，而且每天必須換線二次，每次15分鐘，每天必須更換刀具一次，費時10分鐘；生產線生產週期為0.4分鐘，但實際為0.5分鐘；每天生產數量為600個產品，其中不合格品為50個。請計算其總設備效率。,例題,為什麼會發生事故？Whydoaccidentshappen?安全的三個基本概念Threebasicprincipl