TPM方法(2).ppt

TPMMETHOD TPM GLOBALINDICATOR THETRS TPM RELIABILITYINDICATOR TPM RELIABILITYINDICATOR MTBF meantimebetweenfailure TPM BREAKDOWNSANDMICRO STOPPAGES TPM DATACOLLECTIONS BREAKDOWNRECORDSOFTHELAST6MONTHSPRODUCTIONNOTEBOOKSOPERATOREXPERIENCETHEDATEOFTHELASTTECHNICALMODIFICATIONDONEONONEPARTOFTHEMACHINE Paretoofunsolvedbreakdownsofthelast12monthsEliminatefromthisdatabasethesolvedbreakdownsPriorityistosolvebreakdownsthatrepresentthehigheststoppagesRepetitivebreakdownsmustbehighlighted breakdown1 breakdown2 breakdown3 breakdown4 breakdown5 breakdown6 TPM Breakdowns Paretoanalysisofbreakdowns TPM BREAKDOWNS TREATMENTMETHODOLOGY TPM BREAKDOWNS TREATMENTMETHODOLOGY TPM BREAKDOWNS WEEKLYMEETING SUBJECT breakdownsencounteredduringtheweekPARTICIPANTS supervisorandmaintenancetechnicianGOAL ensurethatthedefinitivemeasureshavebeenimplementedtoavoidanyrecurrenceofbreakdownsPLAN weeklybreakdowninventoryforthepastweekexaminecausesactionstobeimplemented TPM MICRO STOPPAGES CHARACTERISATION Shut down 5mnOftenNorecordsLittleornoperceptionbythegroupEasystart upwithouteliminationofthecause suppressionoftheeffect UnidentifiedcauseLittlemotivationtoeliminatethembecauselittleperceivedimpactonproductionStronglyinvolvestheoperatorsandautomaticinstallationpeoplefortaskswithoutAddedValue TPM MICROSTOPPAGES TREATMENTMETHODOLOGY TPM MICROSTOPPAGES TREATMENTMETHODOLOGY TPM ROLEOFTHEOPERATOR PREVENTIVEMAINTENANCECarryoutproductionoperationscorrectlyandsetupthemachineDoinspectionofthemachineeverydayMaintaintheperformanceofthemachineCleaning Greasing TighteningApplytheselfmaintenanceroutinesheetsCommunicatewithmaintenancedepartmentCarryoutthe counting ofmicro stoppageregistrationsheetsCarryouttherecordingofmicro stoppagescausesParticipatewithengineeringandtrialofnewequipment TPM ROLEOFTHEOPERATOR CURATIVEMAINTENANCEPreparethemachineconditionsforrepairGivetheirfeelingsaboutthemachineandtheiropinionsabouttheworkingconditionsAssisttechniciansduringrepairandheavymaintenanceParticipateinPSGtoidentifysolutionsformicro stoppageandbreakdown TPM MICRO STOPPAGES OPERATORTRAINING TPM PREVENTIVEMAINTENANCETrainandassisttheoperatorsImprovethereliabilityofthemachineandstandardiseidenticalequipmentcapability featurescycletimeImprovemaintainabilityDotechnicalinspectionthatneedexpertiseContinuousimprovementofmaintenanceorganizationParticipateintheengineeringofnewequipment ROLEOFTHEMAINTENANCEDEPARTMENT TPM ExamplesofvisualmeansPositionmarkings machines tooling tools products etc Colourcodingbyfunction productorworkshopLightpaintondirtyobjectsCupboardswithoutdoorsEtc VISUALORGANISATION Experienceanalysis EXAMPLES ObviousTPM VisualmarkforMinandMaxlevelsMarktolocatethestoppositionofamobilepartofamachineRedmarkforpressuremanometerImportantscrewswithnuttighteningarerepairedwithvisualmark see2onpage49 Greaselocationsarehighlightedwitharrows numberedandcolouredPartlistislabelledoncontainers oiltank pumpforgreasingoperations EXAMPLES ObviousTPM FIELDAPPLICATION TPM PILOTWORKSHOP CRITERIALineorbottle neckmachines inordertogaincapacityandavailability Presentingalow MTBF StronglypenalisingtheflowSemi automaticinstallationsconsistingofmanualworkstations theactivityoftheoperatordependsuponthegoodfunctioningoftheinstallation schedules Preliminary 5S operationsimplementationofcleaningprocedureimplementationofinspectionprocedurevisualorganisationTPMmethodologyTRSmeasureMTBFmeasureTreatmentofbreakdownsTreatmentofmicro stoppagesComplementthepreventivemaintenanceprocedure TPM TPM MICROSTOPPAGES TREATMENTMETHODOLOGY TPM MICROSTOPPAGES TREATMENTMETHODOLOGY TPMWORKSHOPSRESULTS FEEDBACKTODESIGN specificationbook setup startofthemachine Up datingofpreventiveroutinedatasheet Collectionofexperience Buildingofpreventivemaintenancebooklet FMECA 5 S TPM Supplieradvices breakdownMicro stoppages Quality Safety PREVENTIVEMAINTENANCEELABORATION FMECA TPM FMECA FailureModesandEffectsCriticalityAnalysisTooltoimproveunderstandingoftheworkingconditionsandthestoprisksofamachineIdentifytheweakpartsofamachineStudyeffectsoffailure ReliabilityMaintainabilityRiskSafety StudyandplansolutionsforcorrectiveandpreventiveactionstoimprovereliabilityRulestooperatethemachinetoitsoptimum TPM FMECA Thinkingapproach CAUSE Whydiditoccur EFFECT Whathashappenedaccordingtothemachineoperator Themachineitself TPM FMECA Quotation Gravity value Minor Midle Critical disastrous Repairtime 5min Repairtimebetween5 15mn Repairtimebetween15 60mn Repairtime 60mnorquality saafetyrisk Frequency value Annual quarterly weekly daily Less1fault year rMax1fault quater Max1fault week 1fault day Detectionprobability Minor Middle Critical disastrous Detectionprobability Previoussignsbeforefailureleadingtopreventivemaintenance Previousindicationsbutnonenoticeablefortheoperator NoPrevioussignbeforefailure Previoussignsbeforefailurebutdifficulttoseebytheoperator Correctivesactions TPM FMECA RiskpriorityindexIPR GxFxD 1 16 64 IPR causesnumber correctivesactions necessary THEMAINTENANCEPLAN TPM Thecurrentmaintenanceplansareestablishedfromrecommendationsfromthemachinemanufactureranddonottakeintoaccountanyspecificuseandrealitiesobservedinthefield THEMAINTENANCEPLAN TPM TheTPMapproachallowsthe OrganisationofobservationsConstructionofmaintenanceplansfromtheobservationofrealityTrainingofoperatorsfromthesenewplans TPM MISSIONANDRESPONSIBILITIESOFATPMLEADER DefinitionsMissionofareaConcisesummaryofwhatthestudiedorganisationsectionshouldcarryoutResponsibilities ofareaanditsmembers Areasofacti