精益管理(设备篇)

1、Measure Analyze Control Improve Lean Six Sigma 全面生产维护 (TPM) uTPM uTPM 团队组织 u设备综合利用率OEE uTPM 活动步骤 RD01120 2 Measure Analyze Control Improve Lean Six Sigma Total Productive Maintenance (TPM) uTPM uTPM Team Organization uOverall Equipment Effectiveness uTPM Phases RD01120 2 Control Total Productive Mai

2、ntenance (TPM)3 精益6 过程改善流程 分析分析控制控制改进改进 定义定义 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

3、测量 定义定义 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 RACI Quad 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 R n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 Control Total Productive Maintenance (TPM)6 Learning Objectives uLearn a method to: nIntegrate operational productivity factors a

4、pplicable in process industries in a single comprehensive measurement nEliminate factors contributing to equipment failure nImprove accessibility for cleaning and maintaining equipment nUse predictive maintenance as a diagnostic tool nImplement maintenance audits Control Total Productive Maintenance

5、 (TPM)7 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; Control Total Productive Maintenance (TPM)8 Whats in It for Me? uOptimized process operations and maintenance uA method to replace the traditional approach of detecting and correcting faulty condition

6、s as they occur uA proactive system which monitors and corrects causes uAn operations strategy based on understanding the cause and effect system affecting the major contributors to process performance Control Total Productive Maintenance (TPM)9 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

7、常识性方法。 Control Total Productive Maintenance (TPM)10 Total Productive Maintenance (TPM) TPM Definition uA common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance. Control Total Productive

8、Maintenance (TPM)11 TPM u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 Control Total Productive Maintenance (TPM)12 TPM uAchieve zero equipment breakdowns and zero defects through prevention uEstablish prevention by nMaintaining normal conditions nEarly detection of abnormalities nQuick

9、 response Control Total Productive Maintenance (TPM)13 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 Control Total Productive Maintenance (TPM)14 Traditional Approach “Re-Active Maintenance” M

10、aintenance “WE FIX” nPerform all maintenance activities nPerform “Fire Fighting” maintenance when a machine breakdown occurs nOrder and administer all tooling, supplies, etc. nPerform Preventive Maintenance Manufacturing “WE OPERATE” nGenerally does not perform any maintenance activities nContacts m

11、aintenance when a machine breakdown occurs nInactive during maintenance activities n“Run it till it breaks” Control Total Productive Maintenance (TPM)15 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

12、检测 n发电机测试 n热感应 n油况分析 Control Total Productive Maintenance (TPM)16 Key Definitions Preventive Maintenance is a time or usage based method of maintaining equipment. Maintenance activities are performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occur

13、ring. nPM Schedules Predictive Maintenance is a situation based method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring. nVibration Analysis nLaser Measuring nUltrasound nGener

14、ator Testing nThermography nOil Analysis Control Total Productive Maintenance (TPM)17 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 Control Total Productive Maintenance (TPM)18 Present State Analysis and Team Organization

15、uAssess Current Operating Conditions nMachine utilization, productivity, etc. nMaintenance repair costs (parts and labor) nPrioritize order of TPM efforts uAssess capabilities of potential TPM Champions and Team Members uSelect TPM Champion and Team Members nEstablish initial kick-off workshop nEsta

16、blish team goal Control Total Productive Maintenance (TPM)19 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 Control Total Productive Maintenance (TPM)20 Typical Operational Process Measurements uUtilization: The ratio o

17、f equipment actual operating time to the total available operating time n= Actual Operating Time/Available Time uEfficiency: The ratio of actual product produced to a standard n= (Actual Parts/Hour)/(Standard Part/Hour) uOutput: Measure of output over a specified time period n= lbs/hr, pieces/hr Con

18、trol Total Productive Maintenance (TPM)21 设备综合利用率OEE u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. Control Total Productive Maintenance (TPM)22 Overall Equipment Effectiveness uOverall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality prod

19、uct at the designed rate. Control Total Productive Maintenance (TPM)23 OEE分解:六大浪费 故障及轻微故障故障及轻微故障 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). 返工浪费返工浪费

20、 用于返修产品或生产出报废产 品所耗用的时间. Control Total Productive Maintenance (TPM)24 OEE Breakdown: The Six Big Losses Breakdowns and Minor Stoppages Malfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages) Setup Any activity related to equipme

21、nt changeover, setup, or cleaning. Idling Time equipment is running but not producing product. Speed Losses Equipment operating at less than standard or design speed due to equipment/product abnormality Quality Factors Activities related to ensuring the quality of the product produced on the equipme

22、nt (in-process checks). Rework Losses The time taken to re-process product or time take to produce un-usable product. Control Total Productive Maintenance (TPM)25 六大浪费的识别练习 识别损失类别 1 2 3 4 5 6 7 8 9 10 机器A在下午1点钟完成一产品装配而在下午2:27开始另一产品的装 配工作 现象 由于电气故障机器A的运转中断31分钟 过程中的质量检查耗时22分钟 机器B上的小装置装卸时间为4分钟 由于机械故障机器

23、X运转中断8分钟 机器Z的清洁时间为47分钟 工件被轧住造成机器C中断3分钟 从取样到送至实验室耗时32分钟 机器Z返修200个工件 由于机油线路泄漏机器D仅能以每小时加工100片产品的速度运行达 不到125片的标准 Control Total Productive Maintenance (TPM)26 Six Big Losses Identification Exercise SCENARIO LOSS IDENTIFICATION 1. Machine A operation is interrupted by an electrical problem for 31 minutes

24、2. An in-process quality check takes 22 minutes 3. Load 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 Control Total Productive Maintenance (TPM)36 Six Team Activities (Cont.) 3. Utilize predictive tools such as vibration analysis to move past reactive type maintenance 4. Increase aw

25、areness and knowledge of equipment to improve productivity and reduce downtime 5. Work with Supply Management and Production Control to insure a constant flow of raw material is available to preclude idling. 6. Develop manning schedules that insure that bottleneck machines are fully staffed Control

26、Total Productive Maintenance (TPM)37 TPM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 Control Total Productive Maintenance (TPM)38 Benefits of TPM uPromotes operator involvement uRestores equipment to a higher performance level uUncover and eliminate

27、premature equipment failures uReduce total manufacturing costs uReduces waste uBuilds a sense of pride in maintaining the equipment uPromotes cooperation and respect between maintenance and production Control Total Productive Maintenance (TPM)39 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 Cont

28、rol Total Productive Maintenance (TPM)40 Areas of Responsibility uLean Six Sigma Team uChampion/Sponsor uTPM Team nOperator nSupervisor nMaintenance Control Total Productive Maintenance (TPM)41 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 Control Total Produ

29、ctive Maintenance (TPM)42 Lean Six Sigma Team Role uDetermine the need for a TPM Project uGather history of maintenance cost, delay, machine availability, and quality problems uInterview Operators to get their prospective Control Total Productive Maintenance (TPM)43 u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

30、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 Control Total Productive Maintenance (TPM)44 Lean Six Sigma Team Role uOn floor activities nAssemble the TPM Team lMaintenance personnel lOperators lFirst line supervision nProvide necessary equipment nHelp team dia

31、gnose abnormalities nAssist skilled trades nCollect copies of defect tags and generate a work list nProvide people resources Control Total Productive Maintenance (TPM)45 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OEE n展示TPM的改善的成就 Control Total Productive Mainte

32、nance (TPM)46 Champion/Sponsor Role uUpon Completion of On Floor Event nGenerate and track completion of work orders nAssist in creation and posting of accurate Periodic Maintenance List nAssist in sustaining the gains nEvaluate Overall Equipment Effectiveness nDisplay TPM improvements Control Total

33、 Productive Maintenance (TPM)47 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 Control Total Productive Maintenance (TPM)48 Supervisors Role uCoach and promote TPM Concepts uMonitor ongoing housekeeping and machine cleanliness uPromote Operator owners

34、hip uEmpower Operators uProvide time for TPM activities uPromote cooperation between Production and Maintenance Control Total Productive Maintenance (TPM)49 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TPM

35、Control Total Productive Maintenance (TPM)50 Maintenance Role “The Specialized Caretakers” uPerform all planned preventative maintenance and take corrective action as needed uUse predictive tools such as vibration analysis, wear particle analysis, and thermography uDocument equipment maintenance his

36、tory uCooperate with Operators and provide technical assistance uPerform equipment overhaul, complex adjustments uProvide special skill tasks, high safety risk tasks uPromote TPM Control Total Productive Maintenance (TPM)51 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

37、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TPM Control Total Productive Maintenance (TPM)52 Operators Role “The First Line Caretaker” uClean and inspect for defects uPerform basic lubrication, multi-point inspection uPerform Periodic Maintenance per approved List uPerform routine cleaning and house

38、keeping as scheduled uIdentify equipment defects as they arise uAssist Maintenance with repairs upon request uPerform basic adjustments uSuggest improvements uPromote TPM Control Total Productive Maintenance (TPM)53 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

39、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 Control Total Productive Maintenance (TPM)54 The 7 Steps of Total Productive Maintenance 1. Perform initial machine cleaning and inspection 2. Identify and tag machine defects and leaks 3. Develop Operator and Maintenance PMs 4. Instruct Opera

40、tors in proper PM techniques 5. Instruct Maintenance Staff in proper PM techniques 6. Implement 5S Housekeeping and Organization 7. Monitor OEE and encourage cooperation Control Total Productive Maintenance (TPM)55 TPM 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 Control

41、Total Productive Maintenance (TPM)56 TPM Safety Habits uFollow/Use nLockout Tagout Procedure nProper Lifting Techniques nElectrical Safety Guidelines nPersonal Protective Equipment lGloves lSafety Shoes lGoggles lRespirators lHearing Protection Control Total Productive Maintenance (TPM)57 TPM 步骤1 初始

42、的机器清洁和检查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 Control Total Productive Maintenance (TPM)58 TPM Step 1 Initial Machine Inspection uPurpose: To Identify needed repairs and tag defects uExecution: nClean machine thoroughly done by all team members nTag and record all repair

43、s needed in a project notebook Control Total Productive Maintenance (TPM)59 TPM 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!” Control Total Productive Maintenance (TPM)60 TPM Step 1 “On Floor Activities” uA Thorough Cleaning Inclu

44、des: nRemoving all chips and other debris nThorough Degreasing nCompressed air for controls nChanging filters, lubricants, etc. nLubricating moving parts and joints nRemoving unnecessary tooling, hardware, supplies, etc. u“You have to get your hands dirty!” Control Total Productive Maintenance (TPM)

45、61 TPM 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机油机油泄漏泄漏橙色橙色 n冷却液泄漏冷却液泄漏绿色绿色 n空气泄漏空气泄漏 黄色黄色 n机器故障机器故障 粉红色粉红色 n电气问题电气问题-蓝色蓝色 Control Total Productive Maintenance (TPM)62 TPM Step 1 “On Floor Activities” uRepair Tag Color Codes uInformation Needed on Tags nAsset number of mach

46、ine nLocation and relative position of defect on machine nName of originator and date nOil Leaks - Orange nCoolant Leaks - Green nAir Leaks - Yellow nMachine Defects - Pink nElectrical Problems - Blue Control Total Productive Maintenance (TPM)63 关注TPM清洁效果 降低停机时间70% u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

47、 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 Control Total Productive Maintenance (TPM)64 Focused TPM Cleaning Effort Reduced Downtime by 70% uBefore Severe Grit and Chips nOut of adjustments nRunning at reduced speeds nConstant breakdowns uAfter Cross-functional Effort nReplaced broken and missing p

48、arts nCorrected the adjustment nReturned to designed speed without incurring scrap Control Total Productive Maintenance (TPM)65 TPM 步骤2 修复机器的缺漏修复机器的缺漏 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 Control Total Productive Maintenance (TPM)66 TPM Step 2 Repair ma

49、chine defects and leaks uPurpose: To repair items found in Step 1 uConsiderations: nChampion/Sponsor insures tagged problems are repaired nActual repairs do not have to be done by team members nProduction Supervisor has to make machine available Control Total Productive Maintenance (TPM)67 TPM 步骤2 u

50、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 Control Total Productive Maintenance (TPM)68 TPM Step 2 uEliminate factors contributing to failure: nSecure and tighten all fasteners, fittings, bolts and screws nReplace any missing part

51、s nReplace any damaged, worn or wrong size parts nResolve all causes of leaks, spillage, spray and splatter uImprove accessibility in order to accomplish: nCleaning nLubricating nAdjusting nChecking/inspecting Control Total Productive Maintenance (TPM)69 TPM 步骤3 建立操作员和维护人员合作的建立操作员和维护人员合作的PM计划计划 u确保发

52、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) Control Total Productive Maintenance (TPM)70 TPM Step 3 Develop Operator PMs and Maintenance PMs uPurpose: To insure adequate preventative maintenance checklists are posted uConsiderations: nTPM Project Team to develop PMs nWho is t

53、o perform tasks nFrequency of tasks (i.e., daily, weekly, etc.) Control Total Productive Maintenance (TPM)71 TPM 步骤4 由操作员执行的由操作员执行的PM作业作业 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 Control Total Productive Maintenance (TPM)72 TPM Step 4 PM activity performed by the Operator

54、 uPurpose: To detect early problems, provide the service interval, and insure 5S procedure is followed uConsiderations: nOperator is responsible to perform PMs as documented nProduction Supervisor to insure PMs are effective Control Total Productive Maintenance (TPM)73 TPM uTPM使操作员更加独立地自我管理和控制; u操作员

55、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 Control Total Productive Maintenance (TPM)74 TPM uTPM makes the operator more independent uThe operator sees the small problems now with the possibility of: nQuickly noting potential problems nCorrecting the current situation nRecognizing norm

56、al conditions nMaintaining the machine in good overall condition Control Total Productive Maintenance (TPM)75 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 Control Total Productive Maintenance (TPM)76 Autonomous

57、 Maintenance uRefers to activities involving operators in the maintenance of their own equipment uHow to make the operator more independent: nMake documentation available nDefine maintenance/manufacturing activities nShow operator how to perform daily checks nTrain in basic operation, maintenance, a

58、nd defect detection nMake daily activities visible nClearly identify items to supervise Control Total Productive Maintenance (TPM)77 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 Control Total Productive Maintenance (TPM)78 Autonomous Mainten

59、ance Implementation uIdentify process critical machinery and equipment uPerform initial cleaning uResolve sources of dirt and contamination uCreate cleaning and lubrication standards uTrain operators on equipment maintenance requirements uImplement a comprehensive maintenance system uEstablish perio

60、dic audits of maintenance effectiveness Control Total Productive Maintenance (TPM)79 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 Control Total Productive Maintenance (TPM)80 Why Clean? uAdverse effects of inadequate cleaning nFailure nProduct def