tpm生产维护_tpm全面生产性维护教材

1,TotalProductiveMaintenance,Manufacturing生产部门,2,ProcessCertification,QCPC,RootCause/CorrectiveAction,Set-UpReduction,StandardWork,MistakeProofing,MarketFeedbackAnalysis,6S,QualityClinicActivity,TotalProductiveMaintenanceACEManufacturingQualifyingLevel,3,程序验证,全面性生产维护,质量诊断程序图表,根本原因修正行动,减少生产准备,标准化作业,防误措施,市场反馈分析,6S,质量诊断行动,全面生产性维护ACE生产部门合格水平,4,TotalProductiveMaintenanceisanequipmentmanagementstrategythatimprovesequipmentefficiency.全面生产性维护是一种设备管理策略以提高设备效率。Or,inotherwords.Treatingtheequipmentlikeitisyourown!或者，换句话说.对待设备就象它是你自己的一样！,TPM全面生产性维护,5,TPMKeyConceptTPM的重要概念,Leftneglected.EquipmentBreaksDown如果不重视设备很快就会坏,TPMsfocusistopreventproblemsbeforeequipmentbreaks.TPM的焦点是要在设备出故障以前防止问题出现。,Inthepast,maintenancefocusedonfixingequipmentafteritbroke.过去，维护工作总是集中在设备坏了以后对其进行修理。,6,TotalProductiveMaintenanceisaNewWayofWorking全面生产性维护是一种全新的工作方式,TPMAttitude:TPM态度：“Weareallresponsibleforourequipment.”“我们所有人对我们的设备负责。”,OldAttitude:过去的态度：“Ioperate,youfix.”“我操作，你修理。”“Ifix,youdesign.”“我处理，你设计。”“Idesign,youoperate.”“我设计，你操作。”,7,Afailureisjustthetipoftheiceberg!故障只是冰山的一个小尖！,HiddenDefects隐藏的问题,Failures故障,Wear,play,slackness,leakage,dust,dirt,corrosion,deformation,adherenceofrawmaterials,surfacedamage,cracking,overheating,vibration,noise,andotherabnormalities.磨损、松驰、泄露、灰尘、污垢、腐蚀变形、原材料粘黏、表面磨损、裂缝、过热、震动、噪音及其它不正常现象。,TipoftheIceberg冰山的顶端,8,TypicalCausesofMachineBreakdown典型的机械故障原因,Gritandchipsinrevolvingorslidingparts旋转或滑动零件中的砂砾和碎片,Contaminationofsensors,contactsandConnectors传感器、触敏器、连接器污染,Dirtanddustoncoolingfan冷却风扇上有灰尘和污垢,Iwonderwhatsgoingtofailnext?我在想下面还会出什么问题呢？,9,TPMTechniquesTPM技术,NormaloperatingRange正常操作范围,Danger!危险！,SimplifyandDocumentTPMActivities.简化并记录TPM行动Usevisualtechniquestoindicatewhatsright/whatswrong.运用直观技术来演示什么是对的/什么是错的。PMCompleted?生产性维护完成了吗？Pressuregage压力计Sightglass视镜Arrowsformotorrotationandfluidcirculation马达旋转和润油指示箭头markingsforsparepartsandfluids.备用零件和润滑油记号MakingPMdevicesmoreaccessible.使生产性维护设备更容易获得Filters,fittingsmademoreaccessible过滤器、各种装置Transparentpanelstofacilitateinspection明了易读的仪表盘便于检查,10,TPMBenefitsTPM的益处,Reducedmaintenancecosts减少维护费用Breakdownmaintenanceis10timesmorecostlythanplannedmaintenance故障维修费用是有计划进行维护费用的10倍以上Enhancedsafety提高安全性Findexposedwires,openbelts,missingguards,loosehardware发现暴露在外的电线、松开的安全带、缺少防护、松开的部件Reducedwaste减少浪费Preventslossoflubricant,compressedair防止润滑油、压缩空气的浪费Improvedquality提高品质Equipmentmorecapableofholdingtolerance设备抗性增强Lessdowntime,longerlife缩短停工时间，寿命更长,11,12TPMQualifyingActivities,12,12项TPM合格行动,13,PURPOSEofLockout/Tagout锁定/标识的目的,Topreventyouorsomeoneelsefrominadvertentlyturningapowersourceonandcausingapotentialinjuryorevendeath.以防你或它人意外开动电源而造成可能的伤害甚至死亡,Lockout/TagoutReview:锁定/标识检查,14,LockoutDevice锁定设备,Alockorotherdevicethatutilizesapositivemeans,toholdanenergyisolatingdeviceinasafepositionandtherebypreventingtheenergizingofamachineorpieceofequipment.一把锁或其它设备，用于使电源设备隔离装置处于一安全的状态，以防止机器或设备的一部分带电。,Lockout/TagoutReview:锁定/标识检查,15,TagoutDefinition标识的定义,Theprocessofsecurelyfasteningatagorprominentwarningsigntoindicatethatboththeenergyisolatingdeviceandtheequipmentbeingcontrolled,mustnotbeoperated.是将一标签或明显的警告标志紧附于设备上以表明不能对电源隔离设备及处于控制下的设备进行操作。Thetagwillalsoincludethenameofthepersonwholockedouttheequipment.该标签应有锁定该装置的人的名字。,Lockout/TagoutReview:锁定/标识检查,16,WARNING警告,NEVERACCEPTLOCKOUTSKEYSFROMANYONE.决不要从它人处接受锁定设备的钥匙。THEASSOCIATERESPONSIBLEFORAPPLYINGTHELOCKORTAGISTHEONLYPERSONAUTHORIZEDTOREMOVETHELOCKORTAG.唯有经授权负责运用锁或标签的人员可以拿掉该锁或标签。,Lockout/TagoutReview:锁定/标识检查,17,ACTIONITEM1:AssessAllEquipment行动内容1：评估所有设备,By“Equipment”wemeananymachinethatwasacapitalexpenseandhasadepreciativevalue.Oranymachinethatisimportanttoyourcell.所谓“设备”是指任何花费了资金并会贬值的机器。或任何对你的部门重要的机器。WeCategorizeallEquipmentbasedonhowUniqueandCriticalitistoensurewefocusattentionontherightequipmentfirst.Payspecialattentiontobottleneckequipment.我们根据设备的独特性和重要性对所有设备进行分类，以确保我们的注意力优先放在正确的设备上。对瓶颈设备给予特殊的关注。,Equipment设备,18,CategoryA:Criticalequipmentforwhichanalternatemachineisnotfeasible,because:A类：不能用其它设备替代的关键设备，因为：Noalternateexists,or无替代设备，或Thealternateisusuallyunavailableduetoutilization,or该替代设备通常正被使用而不能获得，或Itwouldbetoocostly/timeconsumingtotransitiontothealternate太贵/需花太多时间进行替换CategoryC:EquipmentforwhichitisrelativelyeasytofindareplacementoralternateC类：相对容易用其它设备替代的设备Includesmostoff-the-shelfequipment包括最常用的设备Typicallycost$2,500费用低于$2,500Standardspareparts(likedrivemotors)areavailableoff-the-shelf可获得的常用标准备件（如驱动马达）CategoryB:Allotherequipment/machinesB类：所有其它设备/机器,ACTIONITEM1:AssessAllEquipment(cont.)行动内容1：评估所有设备（待续）,19,Inadditiontomachinecategory,createatablelistingallmachinesandadditionalcategories,suchas:除了机器分类，还应作一表格列出所有机器和附加类别，如：Yearofmanufacture产品的生产年份Typeofmachine?Condition?(Good/Fair/Poor)机器类型？状况？（好/一般/差）DoesOperatorPMprocessexists(Hasaservicecardbeencreated?)是否有操作员生产性维护程序（是否有服务卡？）DoesMaintenancePMprocessexist(Doesawrittenmaintenancetasklistexist?)是否有维护生产性维护程序（是否有记录的维护任务表？）Hasthemachineundergoneinitialcleaning?机器是否经过最初的清洁？HasmachinebeenassessedforsafeguardingperSP008?(EH&Sitems)机器是否经过安全装置SP008评估？（EH&S项）,ACTIONITEM1:AssessAllEquipment(cont.)行动内容1：评估所有设备（待续）,20,PossibleCategories:可能的分类：Good:Equipmentwhichretainsallofitsoriginalfunctions,accuracyandreliability.好：设备保持所有原来的功能，精确并可靠。Average:Equipmentwhichhaslostsomeofitsoriginalfunctionsoraccuracy.Itsoutputnormallymeetstherequiredspecifications.一般：设备丧失了一些最初的功能或精确度。其产品符合要求的规范。Poor:Equipmentwhichisnolongeraccurateorreliable.Inordertoproduceacceptableoutput,thisequipmentrequiresoperatorinterventionwellbeyondtheoriginallevel.差：设备不再精确或可靠。为了生产出可接受的产品，要求操作员对设备进行超出原有水平的干涉。,ACTIONITEM1:AssessAllEquipment(cont.)行动内容1：评估所有设备（待续）,21,ACTIONITEM2:WriteMachine-SpecificLockoutProcedures,LockoutproceduresmustbewrittenandimplementedforeachmachineGeneralproceduresareineffectforSullairProceduresneedtobewrittenjointlywithfacilitiesmaintenance,22,行动内容2:将特殊锁定程序写在机器上,锁定程序必须写在每台机器上并予以执行一般程序适用于寿力公司程序必须与设备维护共同写下来,23,ACTIONITEM3/4:OperatorWalkaroundandPMScheduleon100%A/B,OperatorPMdefinedfor100%ofCategoryAandBmachinesAbookorsheetexistswhichdefinesthedaily/weekly/monthlyOperatorPMtasksIncludesafetyequipmentoperation(guards,limitswitches,etc.)inOperatorPM.OperatorPMconductedfaithfully(1monthpriortoaudit)onallEquipmentforwhichitisdefined.,24,行动内容3/4:操作员巡查和所有A/B类设备的PM进度表,操作员PM定义为所有A、B类机器应有写明了操作员每日/周/月的PM任务的书或表包括安全设备（防护装置、限定电闸等）操作员严格地按要求对所有设备进行生产性维护（在审查前一个月）,25,MakeOperatorPMeffective:Usea“Visibleat-a-glance”system(Suchasacolor-codedPMStatusboard)withinthecelltoindicatetheactualstatusof“OperatorPM”tasks.MustbeeasytounderstandNobookorfoldertoread,ACTIONITEM3/4:OperatorWalkaroundandPMScheduleon100%A/B(cont.),26,使操作员进行有效的生产性维护:使用一眼就能看见的系统(如使用颜色代码PM状态板)在单元中表明“操作员PM”任务的实际状态必须容易理解无需翻书或文件夹,行动内容3/4:操作员巡查和所有A/B类设备的PM进度表（待续）,27,CosmeticCleaning禁止化装品,Yougetabetterlookingpieceofequipmentasabenefitbutnotastheonlyobjective你可以使机器看起来更漂亮，但这不是唯一的目的,Youcleantoimproveamachinesperformance-notitsappearance清洁是为提高机器的性能-而不是外表,CleantoInspect清洁以检查InspecttoDetect检查以发现DetecttoCorrect发现以改正,ACTIONITEM5:InitialInspect/Clean100%A/B行动内容5：初步检查/清洁所有A/B类设备,28,Accessiblecomponentscleaned,inspectedandrepaired可用的部件已清洁、检查和修好PMdocumentationisreviewed/updatedPM文件已检查/更新Basicimprovementsareincorporatedtoimprovemaintainabilityandvisual基本的改进用于提高可维护性和形象operatingcondition操作环境,Howaboutthat.Ididntevenknowtherewasagreasefittinghere!那个怎么样。我甚至不知道这儿还有个油脂装置！,ACTIONITEM5:InitialInspect/Cleaning100%A/B(Cont.)行动内容5：初步检查/清洁所有A/B类设备（待续）,29,ACTIONITEM6:TrackDowntimeHistory行动内容6：追溯停工历史记录,MaintenanceDowntimeisthetimeamachineisdownformaintenancepurposes停工维护是指一台机器停工以便维护的时期Unplanned非计划的BreakdownsandRepairs停工