全员生产保养08+P+-+TPM+08Q3+-+bil.ppt

全员生产保养TotalProductiveMaintenance,目录TableofContents,TPM概略TPMOverviewTPM目的TheAimofTPMTPM流程TPMProcess自主保养AutonomousMaintenance计划保养PlannedMaintenance预防工程PreventiveEngineering教育与行动Education&Practice保证质量InsuredQualityTPM改善活动TPMKaizenActivitiesTPM活动进阶AdvancedTPMActivities,TPM概略TPMOverview,何谓TPMWhatisTPM,全员生产保养是这样一个系统TotalProductiveMaintenanceisasystemthat涉及工场/维修人员Involvesbothshopfloorassociatesandmaintenanceassociates支持精益西格玛流程SupportstheLeanSigmaProcess保持设备最佳状态Keepsequipmentinoptimalcondition,为何要实施TPMWhyImplementTPM?,忽视设备基本状况BasicEquipmentconditionsneglected操作维修技能欠佳Insufficientoperatingandmaintenanceskills设备设计固有不足Inherentweaknessinequipmentdesign设备恶化无人监督Overlookeddeterioration没有遵守使用要求Usageconditionsnotobserved,宏观愿景MacroVision,TPM世界性的公司WorldWideCompany,工人自主保养OperatorAutonomousMaintenance,预防保养PreventiveMaintenance,经理支持功能ManagerSupportFunction,工程设备设计改善Eng.Equip.DesignImprovement,品质改善QualityImprovement,全员生产保养TPM,高级管理层领导SML,生产准备2P,西格玛改善SigmaKaizen,TPM目标TPMGoals,零故障ZeroBreakdowns零缺陷ZeroDefects零事故ZeroAccidents全员参与Totalemployeeinvolvement提高机器效率,满足节拍速度AchieveTaktRateatthehighestmachineeffectiveness,TPM与精益西格玛流程TPMandLeanSigmaProcess,精益西格玛LeanSigmaProcess,及时生产JustinTime,自働化Jidoka,畅顺生产ProductionSmoothing,机器可靠MachineReliability机器高效MachineEffectiveness联动操作LinkedOperations人力利用LaborUtilization,制程能力ProcessCapability最佳机况Optimalmachineconditions制程重复ProcessRepeatability防错装置MistakeProofing,实现流畅生产,必须实行TPMTPMisessentialwhenflowproductionisachieved,TPM与传统保养TPMvs.TraditionalMaintenance,每班8小时8hrshift,有效时间=7小时40分Effectiveness=7hrs40min,工人开会:10分钟OperatorMeeting,10min,10min,设备清洁与润滑:10分钟Equipmentcleaning&Lubrication,传统生产班次TraditionalOperatingShift:,实行TPM的班次TPMShift:,本班开始ShiftStart,品质问题Quality,暂停MinorStoppages,故障停机Breakdown,调整Adjustment,本班结束ShiftEnd,每班8小时8hrshift,有效时间=6小时Effectiveness=6hrs,量度指标Metrics,整体设备效率OverallEquipmentEffectiveness(OEE)可用效率Availability性能效率Performance品质效率Quality,保养效率MaintenanceEffectiveness平均故障时间间隔MTTF(Meantimetofailure)平均无故障时间MTBF(Meantimebetweenfailure)平均维修时间MTTR(Meantimetorepair),TPM的目的：TheAimofTPM:,改善设备运行状况Toimprovetheequipmentoperatingcondition维持设备最佳性能与可靠性Tosustainequipmentatanoptimallevelofperformance&reliability延长设备使用寿命Tolengthenthelifeexpectancyofequipment,TPM流程TPMProcess,TPM五大支柱The5PillarsofTPM,自主保养AutonomousMaintenance,计划保养PlanningMaintenance,预防工程PreventiveEngineering,品质Quality,教育与行动Education&Practice,实施TPM十步骤TPMImplementation-10Steps,1.测量工作单元上所有自动设备之OEEMeasureOEEforallautomaticequipmentincells.2.测量各工作单元的节拍时间MeasureTaktrateperformanceforeacharea.3.将单元节拍时间与设备OEE进行比较CorrelatecelltaktrateperformancetoequipmentOEE.4.选择特定机器作为改善重点Selectspecificmachineforkaizenfocus.5.根据OEE六大损失制定改善目标EstablishimprovementgoalrelatedtothesixmajorlossesofOEE.6.选定设备改善专职队员Selectpermanentequipmentimprovementteammembers.7.发动工人进行自主保养及计划保养活动Initiateoperatorautonomousmaintenanceandplannedmaintenanceprograms.8.继续更新检查单,培训工人,保证机器最佳状况Continuetoupdatechecklists,trainoperators,andpursueoptimalmachineconditions.9.为选定设备设立TPM活动之目视表现板EstablishvisualperformanceboardsforTPMactivitiesonselectedequipment.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Checkresultstoimprovementgoalsmonthly.Evaluateneedforadditionalkaizenactivity,settingmoreaggressivegoals,ormodifyingpermanentteammembers.,自主保养AutonomousMaintenance,自主保养AutonomousMaintenance,工人要学习Asystemwhereequipmentoperatorslearnto:进行每日检查Performdailychecks按需润滑设备Lubricateequipmentasneeded更换简单零件Replacesimplecomponents进行机器小修Performminorrepairsonmachines帮助解决问题Assistinproblemsolving,工人是机器发生异常的早期预警系统Operatorsbecometheearlywarningsystemformachineabnormalities,自主保养五步法5StepstoAutonomousMaintenance,1.进行基本清洁活动Performbasiccleaning2.根除肮脏污染源头Eliminatesourcesofdirtandcontamination3.建立清洁润滑标准Establishcleaningandlubricationstandards4.教会设备基本检查,进行自主设备检查TeachgeneralinspectionofequipmentandPerformautonomousequipmentinspection5.培养整齐有序习惯Instillorderlinessandorganization,工人作用RolesofOperators,预防污染Preventdeterioration:维持基本条件Maintainingbasicconditions正确操作设备Operatingequipmentcorrectly判断污染Measuredeterioration:进行检查Inspecting制定标准,坚持执行Developingandadheringtostandards,纠正污染Correctdeterioration:报告问题Reportingproblems协助维修Assistinginrepairs进行微调(按本地合约)Makingminoradjustments(perlocalcontract)加入团队Participateinteams:工作中心团队Workcenterteams解决问题团队Problem-solvingteams,维修人员作用RolesofMaintenancePersonnel,设备保养MaintainEquipment检验(拆卸)Inspect(disassembly)计划保养Plannedoverhauls预防保养Preventivemaintenance教导工人学会特定保养工作Teachselectedmaintenancetaskstooperators,设备改善ImproveEquipment支持可靠性及可维修性改善SupportR&Mimprovement实施预测技术Implementpredictivetechnologies纠正设计不足Correctdesignweaknesses搞好供方合作Partnerwithvendors,设备检查表EquipmentInspectionChecklist,初步清洁InitialCleaning螺母、螺栓等有无松动、摇摆、遗失?Anynuts,bolts,etc.loose,wobblyormissing?活动零件、夹具安装有无窜动?Anyplayinmovingpartsorfixturemountingsection?机器内部有无多余零件?Anyunnecessaryitemslocatedonthebodyofthemachine?润滑系统Lubrication润滑油是否到达滑动部件?Doesoilreachslidingparts?润脂嘴、机油盖等是否损坏、遗失?Anydamagedormissinggreasenipples,oilcaps,etc.?供油装置、管路、接头有无漏油?Anyoilorgreaseleaksfromsupplydevices,pipes,fittings?加油工人有无内外清洁?Areoilerscleaninsideorout?油标是否容易看见?Istheoilleveleasilyvisible?,设备检查表EquipmentInspectionChecklist,液压系统Hydraulics油箱装够油了吗?Istheoiltankfilledtothespecifiedlevel?油泵发出异常噪音吗?Isthepumpemittinganyabnormalnoises?卸荷阀、减压阀、节流阀防松螺母上紧了吗?Arelocknutstightonrelief,reducingandthrottlevalves?卸荷阀、控制装置运作正常吗?Arereliefvalvesandcontrolsoperatingcorrectly?高压管路连接变形或磨损了吗?Anystrainorwearinhighpressurehoseconnections?电器系统Electrical行程开关杠杆能够完全接触吗?Dolimitswitchbarsstrikefully?信号灯、指示灯遗失或烧坏了吗?Anymissingorburnedoutpilotorindicatorlights?配电盘、电器箱有无线路图?Aretherewiringdiagramsinthecontrolpanelsorelectricalboxes?有无多余的、损坏的、压坏的电线或软管?Anyunnecessary,damagedordentedwiresorflexibletubing?,设备检查表EquipmentInspectionChecklist,传动系统PowerTransferDevicesV型皮带碰到带轮槽底了吗?DoV-beltshitthebottomofpulleygrooves?皮带有无损坏、爆裂、破裂?Anydamage,crackingorsplittingofthebelts?滚柱链条的销轴与轴承之间有无足够润滑油?Istheresufficientlubricationbetweenpinsandbushingsofrollerchains?转轴有无过热、振动、噪音?Anyshaftoverheating,vibrationornoise?联接系统有无锁键、夹紧螺栓松动造成的窜动?Anyplayduetoloosekeysorclampingboltsoncouplings?齿轮机构有无过量的躁音、发热、振动?Anyexcessnoise,heatorvibrationingearmechanisms?,设备检查表EquipmentInspectionChecklist,螺母螺栓NutsandBolts登记记号允许松紧度检查吗?Doregistrationmarkspermittightnesschecks?螺母螺栓型号及尺寸正确吗?Arenutsandboltsofthesuitabletypesorsizesused?垫片尺寸正确,且类型相配吗?Arewashersofpropersize,andaretheyconsistentlyused?螺栓有从螺母凸出23圈螺纹吗?Doboltsprotrude23threadsfromthenuts?气动系统Pneumatics截止阀及球阀漏气吗?Anystopvalve,ballvalveleaks?有坏了或多余的手把吗?Anybrokenorunnecessaryhandles?已关闭的阀仍有气流吗?Doesanyairflowthroughclosedvalves?有任何不必要的装置或喉管吗?Areanyunnecessarydevices,hosesorpipespresent?所有喉管都整齐及易于识别吗?Arepipesandhosesorderlyandreadilyidentifiable?压力表指示的都是正确设定的压力吗?Dopressuregaugesclearlyindicatethecorrectsetpressure?,进行基本清洁PerformBasicCleaning,做好清洁检查Cleantoinspect暴露隐藏不足Exposehiddendefects找出脏污源头Determinesourceofcontamination识别难于清洁之处Identifyhardtoreachareas准备蓝色标签工作Prepareforbluetagexercise,消灭脏污源头EliminateSourcesOfDirt&Contamination,脏污原因CausesofContamination:发生液体泄漏Fluidleaks碎片容器很差Poorchipcontainment工作不佳Poor5Spractices工作区有溅洒Workareaspills过滤性能不好Poorfiltration没有清洁标准Nocleaningstandards无工作自豪感Poorworkpride环境问题恶劣Environment,建立清洁与润滑标准EstablishCleaning&LubricationStandards,从工人开始进行基本的清洁、检查及润滑活动Beginbasicoperatorcleaning,inspectingandlubricatingactivities制定临时标准Establishprovisionalstandards进行重点训示Createonepointlesson确定活动频次Establishfrequencyofactivities月检、周检、日检清单Monthly,weeklyanddailychecklist制做检查表Developchecklist,重点训示One-PointLesson,1.0目的/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PerformAutonomousMaintenanceInspection,制定详细的培训计划Developindepthtrainingprogram对工人就以下内容进行培训：Trainoperatorsin:润滑作用/粘性分析Lubrication/ViscosityAnalysis气动系统Pneumatics液压系统Hydraulic电气系统Electricalsystems驱动系统Drivesystems修改目前的重点训示,加入检验检查工作Reviseexistingone-pointlessonstoincludeinspectionchecks,灌输工场整洁条理思想InstillOrderliness&Organization,工场管理与控制Workplacemanagement&control扩展团队活动,做好设备以外的整洁工作Expandteamactivitiesbeyondequipmenttootheraspectsoftheprocess搞好工场整洁,实行目视控制，发现改善机会(第4、5个S)Exposeopportunitiesforimprovedorganization,orderlinessandvisualcontrol(4th&5thS)进行5S评审Perform5Saudits,整洁与条理Organization&Orderliness,目视控制VisualControls,写出已做的活动,展示取得的进步Describesactivitiesundertakenandshowsprogress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Quantifiestheimprovementsmadeagainstagreedmetrics.e.g.(Breakdowns,defects,maintenancecall-outs,linedown-time,etc.)细化实际的改善Detailstheactualimprovementsmade记录待研究项目Recordsissuestobereviewed:没有答复的问题Unansweredquestions需要支援的问题Complexissuessupportrequired,问题公报ProblemNewspaper,问题公报ProblemNewspaper,生产保养完成率PMCompletionRatio,保养小组目视控制MaintenanceGroupVisualControl,活动布告板ActivityBoard,自主保养,全员生产保养活动TPMActivities,进行TPM基础知识培训，评审准备工作TraininTPMfundamentals&ReviewPre-work,实施蓝色标签方法ConductBlueTagExercise异常情况排序Rankabnormalities异常情况维修Repairabnormalities,设备OEM手册评审ReviewequipmentOEMmanuals确定工人自主保养路线,制定检查表CreateOp.AMroute&Checksheet,定义/实施标准化工作Define&ImplementStdWork实现保养反馈循环Implementfeedbacklooptomaintenance进行OEE表现公告ImplementOEEperformanceboard,初步活动自主保养InitialEventsAutonomousMaintenance,TPM的活动TPMActivities,改善前活动(专职队员)Pre-KaizenActivity(PermanentTeam),收集改善活动一个月前的停机数据Collectdowntimedataforonemonthpriortoevent进行设备基本清洁活动Conductinitialcleaningofequipment收集设备规格、OEM手册、机器BOM及图纸Gathermachinespecifications,OEMmanuals,machineBOM,blueprints,改善活动(改善团队成员)KaizenActivity(KaizenTeam),进行两小时的观察Conducttwo-hourobservation清洁脏污源头,贴上蓝色标签CleanandBlueTagsourcesofdirtandcontamination集思广益按实施难易程度排序BrainstormideasPrioritizeaccordingtoimplementationease实施解决方案,消除脏污源头Implementsolutionstoeliminatesourcesofcontamination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StandardizeanddevelopOperatorAutonomousMaintenanceRoutes,CheckSheetsandOne-pointlesson实行OEE表现公告制度ImplementOEEperformanceboard实施设备保养反馈循环Implementequipmentmaintenancefeedbackloop,清洁检查CleanToInspect,改善前Before改善后After,蓝色标签流程BlueTagProcess,识别脏污及异常源头Identifysourcesofcontaminationandmalfunctions每个源头贴上蓝色标签Writeabluetagforeachidentifieditem在机器上靠近源头处挂上蓝色标签Attachbluetagtomachineatlocationofspecificitem在总表上记录蓝色标签资料DocumentTagInformationonSummaryChart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Reviewtagswithmaintenancepersonnelasateam&rankaccordingtoimpact&difficultyofrepair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MaintenancecompletesWhoandWheninformationforabnormalitiesnotrepairedduringkaizeneventandcreatesActionPlan改善小组更新总表状态Teamupdatesstatusofsummarychart在每月改善评审会议上,专职队员评审总表状态Permanentteamreviewsstatusofsummarychartatmonthlykaizenreviewmeeting,蓝色标签BlueTag,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,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DeficienciesTagged,蓝色标签总表BlueTagSummaryChart,机器名称MachineName:OkumaLC20B-344,影响程度/修理难易程度分级Impact/DifficultyRating,目的UsedTo:发现所有浪费迹象,提出可能解决方案Capturewasteinformationandpotentialsolutions按问题清晰程度及实施难易程度,将解决方案进行排序Rate/rankthesolutionsinregardstoresolutionoftheissuesandeaseofimplementation,标签排序矩阵图TagPrioritizationMatrix,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,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/DifficultyMatrix,解决的难易程度,影响,自主保养检查表AMCheckList,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,检查有无明显磨损,进行振动分析,检查液压