全面生产维护

MEASUREANALYZECONTROLIMPROVELEANSIXSIGMA全面生产维护TPMUTPMUTPM团队组织U设备综合利用率OEEUTPM活动步骤RD011202MEASUREANALYZECONTROLIMPROVELEANSIXSIGMATOTALPRODUCTIVEMAINTENANCETPMUTPMUTPMTEAMORGANIZATIONUOVERALLEQUIPMENTEFFECTIVENESSUTPMPHASESRD011202CONTROL精益6过程改善流程分析控制改进定义选定题目列出客户从顾客之声中列出关建需求定出项目焦点和重要指标完成PDF测量绘制业务流程图绘制价值流程图制定数据收集计划测量系统分析收集数据过程能力分析分析提出关键因子区分关键因子验证关键因子评枯每个关键因子对结果的影响量化机会根本原因排序寻找根本原因针对关键因子改进关键因子确认发掘潜在的解决方法选择方案优化方案实行方案控制过程变革和控制制定控制计划计算最终财务过程指标项目过渡给未来项目管理者项目鉴别转化机会测量定义项目编号工具项目定义表净现值分析内部回报率分析折算现金流分析PIP管理过程RACIQUAD表过程图价值分析脑力风暴投票归类法柏拉图因果图/鱼骨图FMEA查检表运行图控制图量具RN消除导致设备故障的因素N使设备的养护清洁更易达成N用预测性保养作为一种检测工具N实施维护审查5TOTALPRODUCTIVEMAINTENANCETPMCONTROLLEARNINGOBJECTIVESULEARNAMETHODTONINTEGRATEOPERATIONALPRODUCTIVITYFACTORSAPPLICABLEINPROCESSINDUSTRIESINASINGLECOMPREHENSIVEMEASUREMENTNELIMINATEFACTORSCONTRIBUTINGTOEQUIPMENTFAILURENIMPROVEACCESSIBILITYFORCLEANINGANDMAINTAININGEQUIPMENTNUSEPREDICTIVEMAINTENANCEASADIAGNOSTICTOOLNIMPLEMENTMAINTENANCEAUDITS6TOTALPRODUCTIVEMAINTENANCETPMCONTROL个人学习意义U流程作业和保养最优化U一种替代传统的在故障发生时检测并修复的方法U一种源头监控和校正的先发系统U一种基于对影响过程性能的主要因素其因果系统的理解工作策略7TOTALPRODUCTIVEMAINTENANCETPMCONTROLWHATSINITFORMEUOPTIMIZEDPROCESSOPERATIONSANDMAINTENANCEUAMETHODTOREPLACETHETRADITIONALAPPROACHOFDETECTINGANDCORRECTINGFAULTYCONDITIONSASTHEYOCCURUAPROACTIVESYSTEMWHICHMONITORSANDCORRECTSCAUSESUANOPERATIONSSTRATEGYBASEDONUNDERSTANDINGTHECAUSEANDEFFECTSYSTEMAFFECTINGTHEMAJORCONTRIBUTORSTOPROCESSPERFORMANCE8TOTALPRODUCTIVEMAINTENANCETPMCONTROL全面生产维护TPM定义U一种用于监控操作,设备保养,消除计划外停机,和提高作业与保养协调程度的常识性方法。9TOTALPRODUCTIVEMAINTENANCETPMCONTROLTOTALPRODUCTIVEMAINTENANCETPMTPMDEFINITIONUACOMMONSENSEAPPROACHTOMONITOROPERATIONS,MAINTAINEQUIPMENT,ELIMINATEUNSCHEDULEDDOWNTIME,ANDIMPROVETHELEVELOFCOOPERATIONBETWEENOPERATIONSANDMAINTENANCE10TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMU通过实施预防实现设备零故障和零缺陷U预防工作将立足于以下方面N维持正常的生产条件N及早发现异常N快速反应11TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMUACHIEVEZEROEQUIPMENTBREAKDOWNSANDZERODEFECTSTHROUGHPREVENTIONUESTABLISHPREVENTIONBYNMAINTAININGNORMALCONDITIONSNEARLYDETECTIONOFABNORMALITIESNQUICKRESPONSE12TOTALPRODUCTIVEMAINTENANCETPMCONTROL传统的反应式维护维修部门“我们只管修理”N执行所有的维修作业N往往是一旦设备发生故障充当救火员的角色N负责定购和保管所有的工具,备件等物资N实施定期检修生产部门”我们只管使用“N通常不作任何维护活动N一旦设备出现故障就与维修部门联系N维修作业中只能停工N一直用到坏了为止13TOTALPRODUCTIVEMAINTENANCETPMCONTROLTRADITIONALAPPROACH“REACTIVEMAINTENANCE”MAINTENANCE“WEFIX”NPERFORMALLMAINTENANCEACTIVITIESNPERFORM“FIREFIGHTING”MAINTENANCEWHENAMACHINEBREAKDOWNOCCURSNORDERANDADMINISTERALLTOOLING,SUPPLIES,ETCNPERFORMPREVENTIVEMAINTENANCEMANUFACTURING“WEOPERATE”NGENERALLYDOESNOTPERFORMANYMAINTENANCEACTIVITIESNCONTACTSMAINTENANCEWHENAMACHINEBREAKDOWNOCCURSNINACTIVEDURINGMAINTENANCEACTIVITIESN“RUNITTILLITBREAKS”14TOTALPRODUCTIVEMAINTENANCETPMCONTROL主要概念定期保养是一种基于时间长短或使用状况对设备进行检修的方法在指定时间或在使用空档间对设备实施检修作业以防止设备发生故障N定期保养计划预测性保养是一种基于设备状态的维护方法根据可视信号或检测技术的情况来实施保养以防止设备发生故障N振动分析N激光探测N超声波检测N发电机测试N热感应N油况分析预测性保养预测性保养定期保养定期保养15TOTALPRODUCTIVEMAINTENANCETPMCONTROLKEYDEFINITIONSPREVENTIVEMAINTENANCEISATIMEORUSAGEBASEDMETHODOFMAINTAININGEQUIPMENTMAINTENANCEACTIVITIESAREPERFORMEDONEQUIPMENTBASEDONDEFINEDTIMEAND/ORUSAGEINTERVALSTOPREVENTEQUIPMENTBREAKDOWNSFROMOCCURRINGNPMSCHEDULESPREDICTIVEMAINTENANCEISASITUATIONBASEDMETHODOFMAINTAININGEQUIPMENTMAINTENANCEACTIVITIESAREPERFORMEDONEQUIPMENTBASEDONVISIBLESIGNALSORDIAGNOSTICTECHNIQUESTOPREVENTEQUIPMENTBREAKDOWNSFROMOCCURRINGNVIBRATIONANALYSISNLASERMEASURINGNULTRASOUNDNGENERATORTESTINGNTHERMOGRAPHYNOILANALYSISPREDICTIVEMAINTENANCEPREVENTIVEMAINTENANCE16TOTALPRODUCTIVEMAINTENANCETPMCONTROL现状分析和团队组织U评估当前的操作条件N机器利用率,生产率等N维修费用配件和人工N对实现TPM的各项工作进行优先次序U评估潜在TPM倡导者及团队成员的实力U挑选TPM倡导者及团队成员N建立初始的实施专门小组N确定团队目标17TOTALPRODUCTIVEMAINTENANCETPMCONTROLPRESENTSTATEANALYSISANDTEAMORGANIZATIONUASSESSCURRENTOPERATINGCONDITIONSNMACHINEUTILIZATION,PRODUCTIVITY,ETCNMAINTENANCEREPAIRCOSTSPARTSANDLABORNPRIORITIZEORDEROFTPMEFFORTSUASSESSCAPABILITIESOFPOTENTIALTPMCHAMPIONSANDTEAMMEMBERSUSELECTTPMCHAMPIONANDTEAMMEMBERSNESTABLISHINITIALKICKOFFWORKSHOPNESTABLISHTEAMGOAL18TOTALPRODUCTIVEMAINTENANCETPMCONTROL典型的设备评价指标U利用率设备实际运转时间与总的可利用时间的比率N实际运行时间/可运行时间U效率实际产量与标准产量的比率N实际产量/小时/标准产量/小时U产出用一特定时间段的产量来衡量N磅/小时,件数/小时19TOTALPRODUCTIVEMAINTENANCETPMCONTROLTYPICALOPERATIONALPROCESSMEASUREMENTSUUTILIZATIONTHERATIOOFEQUIPMENTACTUALOPERATINGTIMETOTHETOTALAVAILABLEOPERATINGTIMENACTUALOPERATINGTIME/AVAILABLETIMEUEFFICIENCYTHERATIOOFACTUALPRODUCTPRODUCEDTOASTANDARDNACTUALPARTS/HOUR/STANDARDPART/HOURUOUTPUTMEASUREOFOUTPUTOVERASPECIFIEDTIMEPERIODNLBS/HR,PIECES/HR20TOTALPRODUCTIVEMAINTENANCETPMCONTROL设备综合利用率OEEU设备综合利用率（OEE）是衡量一台设备按计划速度生产出合格产品的时间占全部时间的百分比21TOTALPRODUCTIVEMAINTENANCETPMCONTROLOVERALLEQUIPMENTEFFECTIVENESSUOVERALLEQUIPMENTEFFECTIVENESSOEEISTHEMEASUREOFTHEPERCENTOFTIMEAPIECEOFEQUIPMENTISPRODUCINGQUALITYPRODUCTATTHEDESIGNEDRATE22TOTALPRODUCTIVEMAINTENANCETPMCONTROLOEE分解六大浪费故障及轻微故障使设备中断运行的时间超过10分钟的故障或者中断时间少于10分钟的轻微故障设置时间浪费任何与设备调整,装配,清洁相关的作业机器空转浪费设备在运转却没有用来生产产品所耗用的时间速度浪费由于设备或产品的异常造成设备以低于标准速度或所设定的速度运转品质原因浪费为确保设备产出品的品质而采取相关的作业过程中检查返工浪费用于返修产品或生产出报废产品所耗用的时间可用水平可用水平AL运行水平运行水平OL质量水平质量水平QL23TOTALPRODUCTIVEMAINTENANCETPMCONTROLOEEBREAKDOWNTHESIXBIGLOSSESBREAKDOWNSANDMINORSTOPPAGESMALFUNCTIONSCAUSINGEQUIPMENTTOSTOPPROCESSINGGREATERTHAN10MINUTESBREAKDOWNSORLESSTHAN10MINUTESMINORSTOPPAGESSETUPANYACTIVITYRELATEDTOEQUIPMENTCHANGEOVER,SETUP,ORCLEANINGIDLINGTIMEEQUIPMENTISRUNNINGBUTNOTPRODUCINGPRODUCTSPEEDLOSSESEQUIPMENTOPERATINGATLESSTHANSTANDARDORDESIGNSPEEDDUETOEQUIPMENT/PRODUCTABNORMALITYQUALITYFACTORSACTIVITIESRELATEDTOENSURINGTHEQUALITYOFTHEPRODUCTPRODUCEDONTHEEQUIPMENTINPROCESSCHECKSREWORKLOSSESTHETIMETAKENTOREPROCESSPRODUCTORTIMETAKETOPRODUCEUNUSABLEPRODUCTAVAILABILITYLEVELALOPERATINGLEVELOLQUALITYLEVELQL24TOTALPRODUCTIVEMAINTENANCETPMCONTROL六大浪费的识别练习25TOTALPRODUCTIVEMAINTENANCETPMCONTROLSIXBIGLOSSESIDENTIFICATIONEXERCISE26TOTALPRODUCTIVEMAINTENANCETPMCONTROLOEE的计算原理承载时间LT设备运转总的可利用时间40HRS可用水平AL运行水平OL质量水平QLOEE73X91X80263312180263289151191289质量原因机器故障及轻微故障,行政事务/非作业时间机器设置与调整速度损失机器空转返工及报废403138427340OEE53ALHRS40313842289HRSOLHRS2893111263HRSQLHRS2633121211HRS27TOTALPRODUCTIVEMAINTENANCETPMCONTROLCALCULATINGOEEELEMENTSLOADINGTIMELTTOTALHOURSAVAILABLEFOREQUIPMENTOPERATION40HRSAVAILABILITYLEVELALOPERATINGLEVELOLQUALITYLEVELQLOEE73X91X80263312180263289151191289QUALITYFACTORSBREAKDOWNSMINORSTOPS,ANDADMINSETUPSPEEDLOSSESIDLINGREWORKANDSCRAP403138427340OEE53ALHRS40313842289HRSOLHRS2893111263HRSQLHRS2633121211HRS28TOTALPRODUCTIVEMAINTENANCETPMCONTROL世界级的OEE性能水平承载时间LT同步计划运转时间及生产性防护时间可用水平AL运行水平OL质量水平QLOEE90X95X99质量原因机器故障及轻微故障,行政事务/非作业时间机器设置与调整速度损失机器空转返工及报废OEE85是世界级的性能水平AL始终保持在90以上OL维持在95以上QL不低于9929TOTALPRODUCTIVEMAINTENANCETPMCONTROLWORLDCLASSOEEPERFORMANCELOADINGTIMELTOPERATIONTIMEANDPMTIMEISSCHEDULEDSYNCHRONIZINGTHETWOAVAILABILITYLEVELALOPERATINGLEVELOLQUALITYLEVELQLOEE90X95X99QUALITYFACTORSBREAKDOWNSMINORSTOPS,ANDADMINSETUPSPEEDLOSSESIDLINGREWORKANDSCRAPOEE85ISWORLDCLASSPERFORMANCETHEALISCONSISTENTLYKEPTATORABOVE90THEOLISMAINTAINEDATORABOVE95THEQLISATORABOVE9930TOTALPRODUCTIVEMAINTENANCETPMCONTROL使设备恢复到可靠状态使设备恢复到可靠状态消除故障消除故障开发开发PM维护保养资料库维护保养资料库消除缺陷消除缺陷阶段I阶段II阶段III阶段IVTPM阶段31TOTALPRODUCTIVEMAINTENANCETPMCONTROLRETURNEQUIPMENTTORELIABLECONDITIONELIMINATEBREAKDOWNSDEVELOPPMINFORMATIONDATABASEELIMINATEDEFECTSPHASEIPHASEIIPHASEIIIPHASEIVTPMPHASES32TOTALPRODUCTIVEMAINTENANCETPMCONTROL六大团队活动1通过小规模的小组活动来提高机器的正常运行时间,消除造成停工的主要根源N机器的启动损失N机器的故障损失N待料损失和生产安排不当带来的停机损失2使操作员熟练地参与如润滑,清洁,故障检验等基本的保养维护33TOTALPRODUCTIVEMAINTENANCETPMCONTROLSIXTEAMACTIVITIES1USESMALLGROUPACTIVITIESTOIMPROVEMACHINEUPTIMEBYELIMINATINGTHEMAJORSOURCESOFDOWNTIMENSTARTUPLOSSESNBREAKDOWNLOSSESNMATERIALANDSCHEDULINGLOSSES2INVOLVETHEMACHINEOPERATORSASWELLASSKILLEDTRADESINBASICPREVENTATIVEMAINTENANCESUCHASLUBRICATION,CLEANING,ANDINSPECTIONFORDEFECTS34TOTALPRODUCTIVEMAINTENANCETPMCONTROL六大团队活动续上页3使用诸如振动分析类的预测工具摈弃过去那种反应式的维护模式4增强对设备的认知和了解以提高生产效能,减少停工时间5使供应管理和生产调度协同工作以确保持续稳定的原材料供应,避免停机待料6规划人员配备以确保瓶颈设备处的满员运作35TOTALPRODUCTIVEMAINTENANCETPMCONTROLSIXTEAMACTIVITIESCONT3UTILIZEPREDICTIVETOOLSSUCHASVIBRATIONANALYSISTOMOVEPASTREACTIVETYPEMAINTENANCE4INCREASEAWARENESSANDKNOWLEDGEOFEQUIPMENTTOIMPROVEPRODUCTIVITYANDREDUCEDOWNTIME5WORKWITHSUPPLYMANAGEMENTANDPRODUCTIONCONTROLTOINSUREACONSTANTFLOWOFRAWMATERIALISAVAILABLETOPRECLUDEIDLING6DEVELOPMANNINGSCHEDULESTHATINSURETHATBOTTLENECKMACHINESAREFULLYSTAFFED36TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM的益处U提升操作员的参与感U使设备恢复至更高的性能水平U发现并消除早期的设备隐患U减少总的制造成本U减少浪费U在保养设备方面树立荣誉感U促进维护和生产部门之间的相互尊重与合作37TOTALPRODUCTIVEMAINTENANCETPMCONTROLBENEFITSOFTPMUPROMOTESOPERATORINVOLVEMENTURESTORESEQUIPMENTTOAHIGHERPERFORMANCELEVELUUNCOVERANDELIMINATEPREMATUREEQUIPMENTFAILURESUREDUCETOTALMANUFACTURINGCOSTSUREDUCESWASTEUBUILDSASENSEOFPRIDEINMAINTAININGTHEEQUIPMENTUPROMOTESCOOPERATIONANDRESPECTBETWEENMAINTENANCEANDPRODUCTION38TOTALPRODUCTIVEMAINTENANCETPMCONTROL职责范围U精益6SIGMA团队U倡导者/发起人UTPM团队N操作员N现场主管N维护人员39TOTALPRODUCTIVEMAINTENANCETPMCONTROLAREASOFRESPONSIBILITYULEANSIXSIGMATEAMUCHAMPION/SPONSORUTPMTEAMNOPERATORNSUPERVISORNMAINTENANCE40TOTALPRODUCTIVEMAINTENANCETPMCONTROL精益6SIGMA团队的任务U确定一个TPM项目的需求U收集有关维护成本,延迟时延或操作延迟,设备利用率以及质量问题的历史数据U与操作员进行深入沟通以了解他们的期望41TOTALPRODUCTIVEMAINTENANCETPMCONTROLLEANSIXSIGMATEAMROLEUDETERMINETHENEEDFORATPMPROJECTUGATHERHISTORYOFMAINTENANCECOST,DELAY,MACHINEAVAILABILITY,ANDQUALITYPROBLEMSUINTERVIEWOPERATORSTOGETTHEIRPROSPECTIVE42TOTALPRODUCTIVEMAINTENANCETPMCONTROLU现场活动N组成TPM团队L负责设备维护的人员L操作员L一线管理人员N准备必要的装备N帮助TPM团队诊断异常N协助跨功能培训N收集整理故障标牌的拷贝并生成工作明细表N提供人力资源方面的支持精益6SIGMA团队的任务43TOTALPRODUCTIVEMAINTENANCETPMCONTROLLEANSIXSIGMATEAMROLEUONFLOORACTIVITIESNASSEMBLETHETPMTEAMLMAINTENANCEPERSONNELLOPERATORSLFIRSTLINESUPERVISIONNPROVIDENECESSARYEQUIPMENTNHELPTEAMDIAGNOSEABNORMALITIESNASSISTSKILLEDTRADESNCOLLECTCOPIESOFDEFECTTAGSANDGENERATEAWORKLISTNPROVIDEPEOPLERESOURCES44TOTALPRODUCTIVEMAINTENANCETPMCONTROL倡导者/发起人的角色U一旦完成现场工作,接下来将N形成工作任务并跟踪其完成情况N协助建立和引入正确的定期维护明细表N协助维持改善结果N评估设备综合利用率OEEN展示TPM的改善的成就45TOTALPRODUCTIVEMAINTENANCETPMCONTROLCHAMPION/SPONSORROLEUUPONCOMPLETIONOFONFLOOREVENTNGENERATEANDTRACKCOMPLETIONOFWORKORDERSNASSISTINCREATIONANDPOSTINGOFACCURATEPERIODICMAINTENANCELISTNASSISTINSUSTAININGTHEGAINSNEVALUATEOVERALLEQUIPMENTEFFECTIVENESSNDISPLAYTPMIMPROVEMENTS46TOTALPRODUCTIVEMAINTENANCETPMCONTROL现场主管的角色U指导并推广TPM概念U监控现场的设备管理,保养及机器清洁工作的进行U激发操作员的主人翁意识U对操作员授权U为TPM活动提供时间方面的准备U促进生产与维护双方的合作47TOTALPRODUCTIVEMAINTENANCETPMCONTROLSUPERVISORSROLEUCOACHANDPROMOTETPMCONCEPTSUMONITORONGOINGHOUSEKEEPINGANDMACHINECLEANLINESSUPROMOTEOPERATOROWNERSHIPUEMPOWEROPERATORSUPROVIDETIMEFORTPMACTIVITIESUPROMOTECOOPERATIONBETWEENPRODUCTIONANDMAINTENANCE48TOTALPRODUCTIVEMAINTENANCETPMCONTROL维护人员的角色“专业的管理者”U有计划的实施所有的定期保养并根据需要采取维修措施U使用振动分析,磨损度分析,热感应等预测工具U建立维护设备的保养记录U与操作员协同工作并提供技术支持U执行设备大修,综合调试U负责执行一些特殊技能的任务,风险安全性高的作业U促进TPM49TOTALPRODUCTIVEMAINTENANCETPMCONTROLMAINTENANCEROLE“THESPECIALIZEDCARETAKERS”UPERFORMALLPLANNEDPREVENTATIVEMAINTENANCEANDTAKECORRECTIVEACTIONASNEEDEDUUSEPREDICTIVETOOLSSUCHASVIBRATIONANALYSIS,WEARPARTICLEANALYSIS,ANDTHERMOGRAPHYUDOCUMENTEQUIPMENTMAINTENANCEHISTORYUCOOPERATEWITHOPERATORSANDPROVIDETECHNICALASSISTANCEUPERFORMEQUIPMENTOVERHAUL,COMPLEXADJUSTMENTSUPROVIDESPECIALSKILLTASKS,HIGHSAFETYRISKTASKSUPROMOTETPM50TOTALPRODUCTIVEMAINTENANCETPMCONTROL操作员角色“一线管理者”U清洁和缺陷检查U执行基本的润滑,多点检测的工作U按照核准清单的项目进行定期保养U按计划执行日常清洁和整理U识别刚刚发生的设备异常U根据需要协助维护人员进行维修U执行基本的调试工作U改善提案U促进TPM51TOTALPRODUCTIVEMAINTENANCETPMCONTROLOPERATORSROLE“THEFIRSTLINECARETAKER”UCLEANANDINSPECTFORDEFECTSUPERFORMBASICLUBRICATION,MULTIPOINTINSPECTIONUPERFORMPERIODICMAINTENANCEPERAPPROVEDLISTUPERFORMROUTINECLEANINGANDHOUSEKEEPINGASSCHEDULEDUIDENTIFYEQUIPMENTDEFECTSASTHEYARISEUASSISTMAINTENANCEWITHREPAIRSUPONREQUESTUPERFORMBASICADJUSTMENTSUSUGGESTIMPROVEMENTSUPROMOTETPM52TOTALPRODUCTIVEMAINTENANCETPMCONTROL全面生产维护的七大步骤1完成初始的机器清洁和检查2识别机器的缺陷和泄漏并加以标示3建立操作员及维护人员的定期检测的PM计划4指导操作员使用正确的保养方法5指导维护人员使用正确的保养方法6贯彻现场5S管理和组织活动7监控OEE并鼓励大家合作53TOTALPRODUCTIVEMAINTENANCETPMCONTROLTHE7STEPSOFTOTALPRODUCTIVEMAINTENANCE1PERFORMINITIALMACHINECLEANINGANDINSPECTION2IDENTIFYANDTAGMACHINEDEFECTSANDLEAKS3DEVELOPOPERATORANDMAINTENANCEPMS4INSTRUCTOPERATORSINPROPERPMTECHNIQUES5INSTRUCTMAINTENANCESTAFFINPROPERPMTECHNIQUES6IMPLEMENT5SHOUSEKEEPINGANDORGANIZATION7MONITOROEEANDENCOURAGECOOPERATION54TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM安全常识U遵守/使用N停工现场标牌警示程序N正确的起重方法N用电安全操作规范N劳保装备L手套L工作鞋L护目镜L防尘口罩L耳塞55TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSAFETYHABITSUFOLLOW/USENLOCKOUTTAGOUTPROCEDURENPROPERLIFTINGTECHNIQUESNELECTRICALSAFETYGUIDELINESNPERSONALPROTECTIVEEQUIPMENTLGLOVESLSAFETYSHOESLGOGGLESLRESPIRATORSLHEARINGPROTECTION56TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM步骤1初始的机器清洁和检查U目的识别需修理处并标示缺陷U执行N彻底清洁机器团队所有成员参与N并将所有需要维修的项目标示并记录57TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSTEP1INITIALMACHINEINSPECTIONUPURPOSETOIDENTIFYNEEDEDREPAIRSANDTAGDEFECTSUEXECUTIONNCLEANMACHINETHOROUGHLYDONEBYALLTEAMMEMBERSNTAGANDRECORDALLREPAIRSNEEDEDINAPROJECTNOTEBOOK58TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM步骤1“现场活动”U彻底的清洁工作包括N清除所有的碎屑及其他残余物N彻底地去除油污N调节压缩空气N更换过滤器,润滑剂等N润滑移动部件及接头处N清理不必要的使用工具,五金器具及备件等U“你的双手肯定会脏兮兮的”59TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSTEP1“ONFLOORACTIVITIES”UATHOROUGHCLEANINGINCLUDESNREMOVINGALLCHIPSANDOTHERDEBRISNTHOROUGHDEGREASINGNCOMPRESSEDAIRFORCONTROLSNCHANGINGFILTERS,LUBRICANTS,ETCNLUBRICATINGMOVINGPARTSANDJOINTSNREMOVINGUNNECESSARYTOOLING,HARDWARE,SUPPLIES,ETCU“YOUHAVETOGETYOURHANDSDIRTY”60TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM步骤1“现场活动”U维修项标示色码U标签上须标示的信息N机器的资产编号N机器位置及故障位置N投入使用的日期及使用人N机油泄漏橙色N冷却液泄漏绿色N空气泄漏黄色N机器故障粉红色N电气问题蓝色61TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSTEP1“ONFLOORACTIVITIES”UREPAIRTAGCOLORCODESUINFORMATIONNEEDEDONTAGSNASSETNUMBEROFMACHINENLOCATIONANDRELATIVEPOSITIONOFDEFECTONMACHINENNAMEOFORIGINATORANDDATENOILLEAKSORANGENCOOLANTLEAKSGREENNAIRLEAKSYELLOWNMACHINEDEFECTSPINKNELECTRICALPROBLEMSBLUE62TOTALPRODUCTIVEMAINTENANCETPMCONTROL关注TPM清洁效果降低停机时间70U之前砂粒及碎屑很严重N无法调试N运行速度降低N故障接连发生U之后跨功能工作的成果N更换缺损的零部件N调试校正N恢复至设计速度且保持品质63TOTALPRODUCTIVEMAINTENANCETPMCONTROLFOCUSEDTPMCLEANINGEFFORTREDUCEDDOWNTIMEBY70UBEFORESEVEREGRITANDCHIPSNOUTOFADJUSTMENTSNRUNNINGATREDUCEDSPEEDSNCONSTANTBREAKDOWNSUAFTERCROSSFUNCTIONALEFFORTNREPLACEDBROKENANDMISSINGPARTSNCORRECTEDTHEADJUSTMENTNRETURNEDTODESIGNEDSPEEDWITHOUTINCURRINGSCRAP64TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM步骤2修复机器的缺漏U目的修复在步骤1中找到的缺漏项目U注意事项N倡导者/发起人需确保标示出的问题得到修复N实际的修复工作不必一定由团队成员来做N生产主管须确保机器能够使用65TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSTEP2REPAIRMACHINEDEFECTSANDLEAKSUPURPOSETOREPAIRITEMSFOUNDINSTEP1UCONSIDERATIONSNCHAMPION/SPONSORINSURESTAGGEDPROBLEMSAREREPAIREDNACTUALREPAIRSDONOTHAVETOBEDONEBYTEAMMEMBERSNPRODUCTIONSUPERVISORHASTOMAKEMACHINEAVAILABLE66TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM步骤2U消除故障因素N固定并拧紧所有的扣件,接头,螺钉及螺母N替换任何缺损的部件N替换任何损坏,磨损及规格不符的零部件N解决所有的渗漏,溢出,喷溅,噪杂等问题U提高如下环节的可操作性N清洁N润滑N调试N检查/测试67TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSTEP2UELIMINATEFACTORSCONTRIBUTINGTOFAILURENSECUREANDTIGHTENALLFASTENERS,FITTINGS,BOLTSANDSCREWSNREPLACEANYMISSINGPARTSNREPLACEANYDAMAGED,WORNORWRONGSIZEPARTSNRESOLVEALLCAUSESOFLEAKS,SPILLAGE,SPRAYANDSPLATTERUIMPROVEACCESSIBILITYINORDERTOACCOMPLISHNCLEANINGNLUBRICATINGNADJUSTINGNCHECKING/INSPECTING68TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM步骤3建立操作员和维护人员合作的PM计划U确保发出完善的定期检测的查检表目的U注意事项N由TPM项目小组建立PM计划N谁来执行任务N任务执行的频率例如每天,每周等69TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSTEP3DEVELOPOPERATORPMSANDMAINTENANCEPMSUPURPOSETOINSUREADEQUATEPREVENTATIVEMAINTENANCECHECKLISTSAREPOSTEDUCONSIDERATIONSNTPMPROJECTTEAMTODEVELOPPMSNWHOISTOPERFORMTASKSNFREQUENCYOFTASKSIE,DAILY,WEEKLY,ETC70TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPM步骤4由操作员执行的PM作业目的尽早发现问题,准备周期保养,遵循5S规程U注意事项N操作员负责按照管理文件执行PM工作N生产主管须确保PM工作的有效实施71TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMSTEP4PMACTIVITYPERFORMEDBYTHEOPERATORUPURPOSETODETECTEARLYPROBLEMS,PROVIDETHESERVICEINTERVAL,ANDINSURE5SPROCEDUREISFOLLOWEDUCONSIDERATIONSNOPERATORISRESPONSIBLETOPERFORMPMSASDOCUMENTEDNPRODUCTIONSUPERVISORTOINSUREPMSAREEFFECTIVE72TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMUTPM使操作员更加独立地自我管理和控制U操作员时时关注小问题的发生就有可能N迅速地发现潜在的问题N修正现有问题N确定状态正常N良好地维持设备整体状况73TOTALPRODUCTIVEMAINTENANCETPMCONTROLTPMUTPMMAKESTHEOPERATORMOREINDEPENDENTUTHEOPERATORSEESTHESMALLPROBLEMSNOWWITHTHEPOSSIBILITYOFNQUICKLYNOTINGPOTENTIALPROBLEMSNCORRECTINGTHECURRENTSITUATIONNRECOGNIZINGNORMALCONDITIONSNMAINTAININGTHEMACHINEINGOODOVERALLCONDITION74TOTALPRODUCTIVEMAINTENANCETPMCONTROL自主维护管理U指的是操作员参与自己所操作的设备的维护作业U怎样使操作员更加自主,实现自我管理N利用文件管理N明确维护/生产作业的规定N明确操作员如何进行日常检测N进行基本的操作,维护及故障检测的培训N使日常作业直观,一目了然N明确识别须监督管理的项目75TOTALPRODUCTIVEMAINTENANCETPMCONTROLAUTONOMOUSMAINTENANCEUREFERSTOACTIVITIESINVOLVINGOPERATORSINTHEMAINTENANCEOFTHEIROWNEQUIPMENTUHOWTOMAKETHEOPERATORMOREINDEPENDENTNMAKEDOCUMENTATIONAVAILABLENDEFINEMAINTENANCE/MANUFACTURINGACTIVITIESNSHOWOPERATORHOWTOPERFORMDAILYCHECKSNTRAININBASICOPERATION,MAINTENANCE,ANDDEFECTDETECTIONNMAKEDAILYACTIVITIESVISIBLENCLEARLYIDENTIFYITEMSTOSUPERVISE76TOTALPRODUCTIVEMAINTENANCETPMCONTROL落实自主维护管理U确定过程实施中的关键机器及设备U执行初步清洁工作U清除脏污及污染源U建立清洁和润滑标准U就设备的保养需求对操作员进行培训U贯彻实施一个综合性的维护系统U对保养效果进行定期审查77TOTALPRODUCTIVEMAINTENANCETPMCONTROLAUTONOMOUSMAINTENANCEIMPLEMENTATIONUIDENTIFYPROCESSCRITICALMACHINERYANDEQUIPMENTUPERFORMINITIALCLEANINGURESOLVESOURCESOFDIRTANDCONTAMINATIONUCREATECLEANINGANDLUBRICATIONSTANDARDSUTRAINOPERATORSONEQUIPMENTMAINTENANCEREQUIREMENTSUIMPLEMENTACOMPREHENSIVEMAINTENANCESYSTEMUESTABLISHPERIODICAUDITSOFMAINTENANCEEFFECTIVENESS78TOTALPRODUCTIVEMAINTENANCETPMCONTROL为什么清洁U不恰当的清洁所带来的负面影响N故障N产品缺陷N加快设备磨损N产量降低U设备磨损N正常磨损尽管正确操作仍然会发生N加快磨损由于误操作及疏忽于保养导致加快磨损79TOTALPRODUCTIVEMAINTENANCETPMCONTROLWHYCLEANUADVERSEEFFECTSOFINADEQUATECLEANINGNFAILURENPRODUCTDEFECTSNACCELERATEDDETERIORATIONNTHROUGHPUTLOSSUEQUIPMENTDETERIORATIONNNORMALDETERIORATIONOCCURSDESPITECORRECTUSENACCELERATEDDETERIORATIONQUICKERDETERIORATIONOCCURRINGDUETOMISUSEINOPERATIONANDNEGLECTOFMAINTENANCE80TOTALPRODUCTIVEMAINTENANCETPMCONTROL清洁可作为磨损检查U清洁可减缓磨损速度U接触设备可发现异常情况U采取保养措施可延长使用寿命,避除故障81TOTALPRODUCTIVEMAINTENANCETPMCONTROLCLEANINGASDETECTIONOFDETERIORATIONUCLEANINGREDUCESACCELERATEDDETERIORATIONUPHYSICALCONTACTWITHEQUIPMENTEXPOSESABNORMALOPERATIONCONDITIONSUPREVENTIVEACTIONTAKENEXTENDSUSEFULLIFEANDAVOIDSBREAKDOWNS82TOTALPRODUCTIVEMAINTENANCETPMCONTROL常见的设备缺陷U断线U软管磨破U漏油U漏气U散热剂泄漏U托架损坏U电线裸露U多余及废弃的器具U防护装置损坏或不见83TOTALPRODUCTIVEMAINTENANCETPMCONTROLTYPICALDEFECTSFOUNDUBROKENFLEXUWORNHOSESUOILLEAKSUAIRLEAKSUCOOLANTLEAKSUBROKENBRACKETSUFRAYEDWIRESUUNNECESSARYANDOBSOLETETOOLINGUDAMAGEDORMISSINGGUARDS84TOTALPRODUCTIVEMAINTENANCETPMCONTROL设备故障U