tpm生产维护_一份国外公司的tpm讲义

1 ASTRATEGYFORPERFORMANCEEXCELLENCE TotalProductiveMaintenance 2 PerformanceExcellenceSeriesTrainingModuleElements ExecutiveOverview Participantmanual ToolsWorkbook KnowledgeBreakthrough Lecturenotes Lecturenotes 3 TableofContentsExecutiveOverview Session1 0Introduction 3Session2 0RoleinLeanManufacturing 8Session3 0RoleoftheOperatorinTPM 18Session4 0AutonomousMaintenanceImplementation 22Session5 0EquipmentPerformance Measurement Management 56 TPM 4 TotalProductiveMaintenance Dotheseproblemssoundfamiliar EquipmentisalwaysbreakingdownOperatingmachinesatratedspeedscreatesdefectsSetupsandadjustmentstaketoolongMinormachinestoppagesareerodingproductivity 5 TotalProductiveMaintenance Aseriesofmethodstoensurethatprocessmachinesarealwaysabletoperformtheirfunctionssothatproductionisneverinterrupted 6 TotalProductiveMaintenance Whatitis 1 Optimizesequipmentefficiency2 ImplementsacompanywidePreventiveMaintenancesystem3 Involvesproductionequipmentdesigners operators andmaintenancedepartmentpersonnel4 InvolvementfromManagementdowntofloorworkers5 Implementedthroughsmall selfdirectedteamactivities 7 TotalProductiveMaintenance TypicalsuccessresultsafterimplementationofTPM Breakdowns 1 30to1 100ofpriorlevelMachinedefects 1 30to1 40ofpriorlevelProductivity 30 100percentincrease source K Shirose TPMForWorkshopLeaders p 10 8 PerformanceExcellence ExpandingtheStrategythroughTPM IntroductionRoleinLeanManufacturingRoleoftheOperatorinTPMAutonomousMaintenanceImplementationEquipmentPerformance MeasurementandManagement TPM 9 TheNinetypesofwaste OverproductionDelays waitingtime TransportationProcessInventoriesMotionsDefectiveproductsUntappedresourcesMisusedresources 9Wastes TPMtargetsreductionoftheseequipmentorientedwastes 10 Yesterday Problem machinebreakdown getaroundtheproblemSolution Workinbatches Weusethetimeitworkstomassproduce TPM ALeanManufacturingMethod TPMandone pieceflow Today Objective OnepieceflowQualityeverytimeMeans TPM Weorganizesoitworkscontinuously 11 GoalsofTPM Achievezeroequipmentbreakdownsandzerodefectsthroughprevention EstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponse 12 PresentConditions OperatorsviewmachinesasresponsibleformajorproductionAndlimittheirrolestoequipmentoperationandinspectingforqualityWhilemaintenanceworkersviewtheirfunctionasrespondingtorecurringbreakdowns 13 MaintenanceApproaches TimeBasedorPlannedMaintenance Periodicallyscheduledmaintenanceactions PredictiveMaintenance Maintenanceactionperformedresultingfromevaluationofequipmentcondition CorrectiveMaintenance Maintenanceactionperformedtorestoreoptimalequipmentfunction PreventiveMaintenance AcombinationofTimebasedandPredictiveMaintenanceandactionstakentosustainoptimalequipmentperformanceandprecludebreakdowns 14 EarlyEquipmentManagement Optimizesequipmentselectionthrough EquipmentLifeCycleCostAnalysis analysisofthesumofallcosts directandindirect associatedwithanitemofequipmentthroughoutitsperiodofuse MPDesign activitywhichisfocusedonminimizingfuturemaintenancecostsandproductionlossesofequipmentatthedesignstage 15 TotalProductiveMaintenance WithoutTPM WithTPM MED IndustrialEngineering Maintenance MED IndustrialEngineering Operation Maintenance Theoperatoroperates maintenancemaintains etc Sharedresponsibilities Operation 16 EquipmentMaintenanceResponsibilities MED IndustrialEngineering Autonomousmaintenance BreakdownmaintenancePlannedmaintenancePredictivemaintenance Maintenanceprevention 17 TotalProductiveMaintenance Equipmentinbetterworkingcondition Decreaseofbreakdowns Decreaseofin processadjustments Optimizationofoperationspeed Manufacturingdefects Lead time Qualitythefirsttime 18 PerformanceExcellence ExpandingtheStrategythroughTPM IntroductionRoleinLeanManufacturingRoleoftheOperatorinTPMAutonomousMaintenanceImplementationEquipmentPerformance MeasurementandManagement TPM 19 TotalProductiveMaintenance TPM thetotalapproachTheoperatoristhefirstlinecaretakerMaintenancepersonnelarethespecializedcaretakers 20 DivisionofMaintenanceDutiesbetweenProductionandMaintenance Dependingonknowledgeandskillsrequired responsibilityforequipmentmaintenancetasksneedstobedefined MaintenanceTechnicianProductionOperator Equipmentoverhaul Basiclubrication Specialskilltasks Generalcleaning Complexadjustments Multi pointinspection Highsafetyrisktasks Basicadjustments 21 MaintenanceTaskAllocationbetweenProductionandMaintenance MaintenanceTechnicians ProductionOperators Autonomousmaintenanceimplementation Volumeofmaintenancetasks 22 PerformanceExcellence ExpandingtheStrategythroughTPM IntroductionRoleinLeanManufacturingRoleoftheOperatorinTPMAutonomousMaintenanceImplementationEquipmentPerformance MeasurementandManagement TPM 23 Autonomousmeans independent Autonomousmaintenancereferstoactivitiesinvolvingoperatorsinthemaintenanceoftheirownequipment AutonomousMaintenance 24 AutonomousMaintenance Howtomaketheoperatormoreindependent Makethedocumentationavailable manual maintenanceschedule logbook Asateam definemanufacturing maintenance MEDproductivemaintenanceactivities Showoperatorhowtoperformdailychecksandtakecorrectiveactions Traininbasicoperation maintenanceanddefectdetectiontechniques MakedailyactivitiesvisibleClearlyidentifyitemstosupervise 25 ProcessCriticalMachinery Equipment Maptheprocessandidentifycriticalequipment Turning Drilling Cutting Cleaning Stripping Painting Shipping 26 Adverseeffectsofinadequatecleaning 27 Adverseeffectsofinadequatecleaning Failure equipmentfailureresultingfromdirtandcontaminationaffectingprecisionProductdefects contaminationofproductsordefectsarisingfrominsufficientcleaningAccelerateddeterioration dirtandscalebuildupshorteningusefulequipmentlifeThroughputloss reductioninoutputduetolossofoperationspeedduetogrimeandcontamination 28 EquipmentDeterioration Normaldeterioration deteriorationthatoccursdespitecorrectuseandmaintenanceAccelerateddeterioration quickerdeteriorationoccurringduetomisuseinoperationandneglectofmaintenance 29 Performance Time EquipmentBreakdown 100 TimeandDeteriorationofPerformance Needfordetectionofperformancedecline 30 CleaningasDetectionofDeterioration Cleaning reducesaccelerateddeteriorationPhysicalcontactwithequipment exposesabnormaloperatingconditions i e vibration noisybearings leaks overheating frayedbelts inoperativeindicators etc Preventiveactiontaken extendsusefullifeandavoidsbreakdowns 31 Agoodclean upallowsforagoodinspection Noise Vibration Heat Oil Dirt Quicklydetect Anddocument CleaningasDetectionofDeterioration 32 FactorsContributingtoEquipmentFailure Equipmentfailures Looseparts Vibration Contamination Improper InadequateLubrication 33 EliminateFactorsContributingtoFailure Secureandtightenallfasteners fittings boltsandscrewsReplaceanymissingpartsReplaceanydamaged wornorwrongsizepartsResolveallcausesofleaks spillage sprayandscatter ImproveaccessibilityinordertoaccomplishCleaningLubricatingAdjustingChecking 34 AutonomousMaintenance TaggingAbnormalities 35 Cleaningwilluncoverproblemsandundesirableconditions AttachtagtomakeproblemvisibleResolvesproblemspromptlyandremovetags Documentplanstoaddressthosethatcan tberemovedimmediately AutonomousMaintenance 36 BeforeTagsareRemoved AskThe5 Whys Problem Oilleaksfromthehydraulicpress1 Why Cloggedfilter2 Why Oilwasdirty3 Why Metalfilingsgotintooil4 Why Oilfillcapmissing5 Why Misplaced lost Findtherootcause Solution Oilfillercapattachedtofillerneckbyachain Poka Yoke 37 EquipmentPerformanceLosses Downtimelosses timelosttoequipmentbreakdowns machineadjustmentsEfficiencylosses timelosttostartupandoperatingcyclespeedslessthanidealDefectlosses timelosttomachinerelatedqualitydefectsandrecycling 38 EquipmentPerformanceLosses 39 AssignableLossversusCommonLoss Defectrate Time Assignableloss correctedbyrestoringtooriginalconditions Commonloss reducedbyachievingoptimalconditions 40 ImportanceofLubrication Someexpertsestimate60 ofmachinebreakdownsassociatedwithmovingpartsareduetolackoforimproperlubricationpractices 41 LubricationManagement Theneedtolubricateequipmentcorrectlyandconsistentlyaccordingtousagewithcorrectlubricantsinthecorrectamountatspecifiedfittingsatspecifiedtimeintervalsensuringcoverageofcontactareas 42 VisualManagementofLubricants GreenBlueOrangeRedw Whitestripe OilGreaseHydraulicfluidSilicone 43 MaintenanceChecklists TPMVERIFICATIONLISTAtTheBeginningofEachShiftHydraulicPressureLeaks oil fluids CapsandhosesSwitchesLightsandlampsBodyNoises vibrationAtTheEndofEachShiftCleanMakeentryinmaintenancebook 44 1 2 3 4 5 6 7 8 9 10 ExampleCleaningandLubricationforAutonomousMaintenance 45 BasicTraininginEquipment Conductequipmenttrainingforleaders Leadersthentraingroupmembers Operatorsimplementtrainingtocorrectabnormalitiesandimproveequipmentperformance Implementvisualcontrols 46 ExampleSkillsMatrix BasicTraininginEquipment 47 OnePointLesson Purpose Toprovidespecificknowledgeaboutasingletopicofimportance Facilitateteamtraininginaneasymanner Discussedontheshopfloor Types KnowledgeImprovementsSolutionstoproblems 48 ObjectName FastenersSubject IdentificationNumber Generictypes Dateprepared 4 17 00By JohnClarkApproved TinaJones One PointLessonSheet DepartmentDatetrainedName Purpose Identificationoffastenerhardwareforrepairsandorderingofreplacements Maint Purchasing InventoryStores x OnePointLesson Production 49 TPMDeploymentEffectivenessthroughOverlappingTeams PlantManager StaffManager StaffManager StaffManager Dept Manager Dept Manager Dept Manager Supervisor Supervisor Supervisor Supervisor Operator Operator Operator Operator Operator MaximizingCommunication Coordination Teamleaders 50 BuildaTimeBasedMaintenanceSystem Determineequipmentfortimebasedmaintenance Developmaintenancecriteriaandintervals Trainformaintenanceimplementation Executeperiodicmaintenance No Revisemaintenanceinstructions partsprovisioning 51 EstablishanEquipmentFailureDatabase Gatherandmanageequipmentfailureinformation Analyzefortrendsandpatternsofrecurrence Developandissueperiodicequipmentfailuresummaryreports Includefailuresummaryreportsasameetingagendaitemforregularreview discussionandimprovementactionplanning 52 PredictiveMaintenanceasaDiagnosticTool 53 PredictiveMaintenanceDeployment DetermineequipmentsuitableforPredictiveMaintenance Developdiagnosticmethodsandinstructions Diagnoseequipmentasdefined Executerepair Yes Revisemaintenanceinstructions partsprovisioning Documentrepairinformation Evaluateandrevisediagnosticcriteria 54 MaintenanceAudits AuditsarethemostimportantfactorinthesuccessfulimplementationofanAutonomousMaintenanceProgram They VerifysuccessofimplementationateachstepProvideimprovementfeedbackInsti