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2022年11月15日星期二精益生产之全面生产维护TPM(中英文版)2962275MeasureAnalyzeControlImproveLeanSixSigmaTotalProductiveMaintenance(TPM)TPMTPMTeamOrgani

zationOverallEquipmentEffectivenessTPMPhasesRD011202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•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&R•Cp&Cpk•供应链加速器分析•多变动图i•盒状图•交互作用图•回归分析•ANOVA•C&E矩阵图•FMEA•脑力风暴•拉系统•减少设置•TPM•流程图•标杆管理•亲和图•DOE•假设检验•力场分析图•树状图•甘特图•查检

表•运行图•柱状图•散布图•控制图•柏拉图•互动回顾•愚巧法Revised1-12-02TotalProductiveMaintenance(TPM)LeanSixSigmaImprovementProcessRoadMapAnal

yzeControlImproveDefine•IdentifyProblem•DevelopListofCustomers•DevelopListofCTQ’sfromVoiceoftheCustomer•FinalizeProjectFoc

usandKeyMetrics•CompletePDFMeasure•MapBusinessProcess•MapValueStream•DevelopDataCollectionPlan•ConductMe

asurementSystemAnalysis•CollectData•ConductProcessCapabilityAnalysisAnalyze•ProposeCriticalX’s•PrioritizeCriticalX’s•VerifyCriti

calX’s•EstimatetheImpactofEachXonY•QuantifytheOpportunity•PrioritizeRootCauses•ConductRootCauseAnalysisonCriticalX’sImprove•CriticalX’sConfir

med•DevelopPotentialSolutions•SelectSolution•OptimizeSolution•PilotSolutionControl•ImplementProcessChangesandControls•WriteCont

rolPlan•CalculateFinalFinancial/•ProcessMetrics•TransitionProjecttoFutureOwners•IdentifyProject•TranslationOpportunitiesMeasureDefine

•ProjectIDTools•ProjectDefinitionForm•NetPresentValueAnalysis•InternalRateofReturnAnalysis•DiscountedCashFlowAnalysis•PIPManagementProcess•RACI•QuadC

harts•ProcessMapping•ValueAnalysis•Brainstorming•Multi-VotingTechniques•ParetoCharts•C&E/FishboneDiagrams•FMEA•CheckSh

eets•RunCharts•ControlCharts•GageR&R•Cp&Cpk•SupplyChainAcceleratorAnalysis•Multi-Vari•BoxPlots•InteractionPlots•Regression•ANOVA•C&

EMatrices•FMEA•Brainstorming•PullSystems•SetupReduction•TPM•ProcessFlow•Benchmarking•Affinity•DOE•HypothesisTesting•Forc

eField•TreeDiagrams•GanttCharts•CheckSheets•RunCharts•Histograms•ScatterDiagrams•ControlCharts•ParetoCharts•InteractiveReviews•Poka-YokeRevis

ed1-12-02TotalProductiveMaintenance(TPM)课程目的学习一种方法以便:将作业流程中的起作用的所有生产要素整合为一个单一综合的衡量值（OEE）;消除导致设备故障的因素;使设备的养护清

洁更易达成;用预测性保养作为一种检测工具;实施维护审查TotalProductiveMaintenance(TPM)LearningObjectivesLearnamethodto:Integra

teoperationalproductivityfactorsapplicableinprocessindustriesinasinglecomprehensivemeasurementEliminatefactorscontributingtoequipmentfailure

ImproveaccessibilityforcleaningandmaintainingequipmentUsepredictivemaintenanceasadiagnostictoolImplementmaintenanceauditsTotalProd

uctiveMaintenance(TPM)个人学习意义流程作业和保养最优化一种替代传统的在故障发生时检测并修复的方法;一种源头监控和校正的先发系统;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;TotalProductiveMaintenance(TPM)What’sinItforMe?OptimizedprocessoperationsandmaintenanceAmethodtoreplacethetraditio

nalapproachofdetectingandcorrectingfaultyconditionsastheyoccurAproactivesystemwhichmonitorsandcorrectscause

sAnoperationsstrategybasedonunderstandingthecauseandeffectsystemaffectingthemajorcontributorstoprocessperformanceTotalP

roductiveMaintenance(TPM)全面生产维护(TPM)定义: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。TotalProductiveMaintenance(TPM)TotalProduct

iveMaintenance(TPM)TPMDefinitionAcommonsenseapproachtomonitoroperations,maintainequipment,eliminateunscheduleddowntime,andimprovethe

levelofcooperationbetweenOperationsandMaintenance.TotalProductiveMaintenance(TPM)TPM通过实施预防实现设备零故障和零缺陷;预防

工作将立足于以下方面:维持正常的生产条件及早发现异常快速反应TotalProductiveMaintenance(TPM)TPMAchievezeroequipmentbreakdownsan

dzerodefectsthroughpreventionEstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponseTotalProductiveMainten

ance(TPM)传统的反应式维护维修部门–“我们只管修理”执行所有的维修作业往往是一旦设备发生故障充当救火员的角色;负责定购和保管所有的工具,备件等物资;实施定期检修生产部门–”我们只管使用“通常不作任何维护活动一旦设备出现故障就与维修部门联系维修作业中只

能停工;一直用到坏了为止TotalProductiveMaintenance(TPM)TraditionalApproach“Re-ActiveMaintenance”Maintenance–“WEFIX”Pe

rformallmaintenanceactivitiesPerform“FireFighting”maintenancewhenamachinebreakdownoccursOrderandadministeralltooling,supplies,etc.PerformPreventiv

eMaintenanceManufacturing–“WEOPERATE”GenerallydoesnotperformanymaintenanceactivitiesContactsmaintenancewhenamachinebreakdowno

ccursInactiveduringmaintenanceactivities“Runit'tillitbreaks”TotalProductiveMaintenance(TPM)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.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.振动分析激光探测超声波检测发电机测试热感应油况分析预测性保养定期保养T

otalProductiveMaintenance(TPM)KeyDefinitionsPreventiveMaintenanceisatimeorusagebasedmethodofmaintaining

equipment.Maintenanceactivitiesareperformedonequipmentbasedondefinedtimeand/orusageintervalstoprevente

quipmentbreakdownsfromoccurring.PMSchedulesPredictiveMaintenanceisasituationbasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedo

nequipmentbasedonvisiblesignalsordiagnostictechniquestopreventequipmentbreakdownsfromoccurring.VibrationAnal

ysisLaserMeasuringUltrasoundGeneratorTestingThermographyOilAnalysisPredictiveMaintenancePreventiveMaintenanceTotalProductiveMain

tenance(TPM)现状分析和团队组织评估当前的操作条件:机器利用率,生产率等;维修费用(配件和人工)对实现TPM的各项工作进行优先次序评估潜在TPM倡导者及团队成员的实力挑选TPM倡导者及团队成员建立初始的实施专门小组确定团队目标TotalProductiveMain

tenance(TPM)PresentStateAnalysisandTeamOrganizationAssessCurrentOperatingConditionsMachineutilization,produ

ctivity,etc.Maintenancerepaircosts(partsandlabor)PrioritizeorderofTPMeffortsAssesscapabilitiesofpotentialTPMChampionsandTeamMembersSel

ectTPMChampionandTeamMembersEstablishinitialkick-offworkshopEstablishteamgoalTotalProductiveMainte

nance(TPM)典型的设备评价指标利用率:设备实际运转时间与总的可利用时间的比率;=实际运行时间/可运行时间效率:实际产量与标准产量的比率=(实际产量/小时)/(标准产量/小时)产出:用一特定时间段的产量来衡量=磅/小时,件数/小时TotalProductive

Maintenance(TPM)TypicalOperationalProcessMeasurementsUtilization:Theratioofequipmentactualoperatingti

metothetotalavailableoperatingtime=ActualOperatingTime/AvailableTimeEfficiency:Theratioofactualproductproducedtoastandard=(ActualParts/Hour)/

(StandardPart/Hour)Output:Measureofoutputoveraspecifiedtimeperiod=lbs/hr,pieces/hrTotalProductiveMaintenance(TPM)设备综合利用率OEE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.TotalProductiveMaintenance(TPM)OverallEquipmentEffectivenessOverallEquipmentEffectiveness(OEE)isthemeasureof

thepercentoftimeapieceofequipmentisproducingqualityproductatthedesignedrate.TotalProductiveMaintenance(TPM)OEE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(AL)运行水平(OL)质量水平(QL)TotalProductiveMaintenance(TPM)OEEBreakdown:TheSixBigLo

ssesBreakdownsandMinorStoppagesMalfunctionscausingequipmenttostopprocessinggreaterthan10minutes(breakd

owns)orlessthan10minutes(minorstoppages)SetupAnyactivityrelatedtoequipmentchangeover,setup,orcleaning.IdlingTimeequipme

ntisrunningbutnotproducingproduct.SpeedLossesEquipmentoperatingatlessthanstandardordesignspeedduetoequipment/productabnormalityQualityFa

ctorsActivitiesrelatedtoensuringthequalityoftheproductproducedontheequipment(in-processchecks).ReworkLossesThetimetakentore-processproductor

timetaketoproduceun-usableproduct.AvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)TotalProductiveMaintenance(TP

M)六大浪费的识别练习识别损失类别12345678910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8.Asampleistakenandtransportedtothe

labtaking32minutes9.200piecesarere-processedonmachineZ10.MachineDrunsat100pc/hrnot125pc/hrduetoleakyoillinesTotalProducti

veMaintenance(TPM)SixBigLossesIdentificationExerciseSCENARIOLOSSIDENTIFICATION1.MachineAoperationisinterruptedbyanelectricalproblemf

or31minutes2.Anin-processqualitychecktakes22minutes3.Load&unloadtimebetweenwidgetsonmachineBis4minutes4.MachineXoperationisinterruptedo

f8minutesduetoamechanicalproblem5.CleaningtimeonmachineZis47minutes6.JammedpiececausesmachineCstoppageof3minutes

7.MachineAcompletesaloadat1:00pmandbeginsanotherload(differentproduct)at2:27pm8.Asampleistakenandtransportedtothelabtaking32minutes9.200piecesarer

e-processedonmachineZ10.MachineDrunsat100pc/hrnot125pc/hrduetoleakyoillinesTotalProductiveMaintenance(TPM)OEE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(QL)OEE73%x91%x80%26.3-3.1-2.1=80%26.328.9-1.5-1.1=91%28.9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40-3.1-3.8-4.2=73%40OEE=53%ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrsTotalProductiveMaintenan

ce(TPM)CalculatingOEEElementsLoadingTime(LT)TotalHoursAvailableforEquipmentOperation=40hrsAvailabilityLevel(AL)OperatingLevel(OL)Qualit

yLevel(QL)OEE73%x91%x80%26.3-3.1-2.1=80%26.328.9-1.5-1.1=91%28.9QualityFactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrap40-3

.1-3.8-4.2=73%40OEE=53%ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrsTotalProductiveMaintenance(TPM)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(QL)OEE90%x95%x99%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OEE=85%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99%TotalProductiveMaintenance(TPM)WorldClassOEEPerformanceLoadingTime

(LT)OperationTimeandPMTimeisscheduledsynchronizingthetwoAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE90%x95%x99%Quality

FactorsBreakdownsMinorStops,andAdmin.SetupSpeedLossesIdlingReworkandScrapOEE=85%isWorldClassPerformanceTheALisconsistentlykep

tatorabove90%TheOLismaintainedatorabove95%TheQLisatorabove99%TotalProductiveMaintenance(TPM)使设备恢复到可靠状态消除故障开发PM维护保养资料库消除缺陷阶段I阶段II

阶段III阶段IVTPM阶段TotalProductiveMaintenance(TPM)ReturnEquipmenttoReliableConditionEliminateBreakdownsDevelopPMInformationDatabaseEliminateDefectsP

HASEIPHASEIIPHASEIIIPHASEIVTPMPhasesTotalProductiveMaintenance(TPM)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:机器的启动损失机器的故障损失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.TotalProductiveMaintenance(TPM)SixTeamActivities1.Usesmallgroupactivitiestoimprovemachineuptimebyeliminatingthe

majorsourcesofdowntime.StartupLossesBreakdownLossesMaterialandSchedulingLosses2.Involvethemachineoperatorsaswellasskilledtradesinbasicpreventat

ivemaintenancesuchaslubrication,cleaning,andinspectionfordefects.TotalProductiveMaintenance(TPM)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TotalProductiveMainte

nance(TPM)SixTeamActivities(Cont.)3.Utilizepredictivetoolssuchasvibrationanalysistomovepastreactivety

pemaintenance4.Increaseawarenessandknowledgeofequipmenttoimproveproductivityandreducedowntime5.WorkwithSupplyManagementandProductio

nControltoinsureaconstantflowofrawmaterialisavailabletoprecludeidling.6.Developmanningschedulesthatinsurethatbottleneckmachinesarefullystaff

edTotalProductiveMaintenance(TPM)TPM的益处提升操作员的参与感使设备恢复至更高的性能水平发现并消除早期的设备隐患减少总的制造成本减少浪费在保养设备方面树立荣誉感促进维护和生产部门之间的相互尊重与合作

TotalProductiveMaintenance(TPM)BenefitsofTPMPromotesoperatorinvolvementRestoresequipmenttoahigherperformancelevelUncoveran

deliminateprematureequipmentfailuresReducetotalmanufacturingcostsReduceswasteBuildsasenseofprideinmaintainingtheequipmentPromotescooperationandre

spectbetweenmaintenanceandproductionTotalProductiveMaintenance(TPM)职责范围精益6Sigma团队倡导者/发起人TPM团队操作员现场主管维护人员T

otalProductiveMaintenance(TPM)AreasofResponsibilityLeanSixSigmaTeamChampion/SponsorTPMTeamOperatorSupervisorMaintenanceTotalP

roductiveMaintenance(TPM)精益6Sigma团队的任务确定一个TPM项目的需求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与操作员进行深入沟通以了解他们的期望TotalProdu

ctiveMaintenance(TPM)LeanSixSigmaTeamRoleDeterminetheneedforaTPMProjectGatherhistoryofmaintenancecost,delay,machineava

ilability,andqualityproblemsInterviewOperatorstogettheirprospectiveTotalProductiveMaintenance(TPM)现场活动组成T

PM团队负责设备维护的人员操作员一线管理人员准备必要的装备帮助TPM团队诊断异常协助跨功能培训收集整理故障标牌的拷贝并生成工作明细表提供人力资源方面的支持精益6Sigma团队的任务TotalProductiveM

aintenance(TPM)LeanSixSigmaTeamRoleOnflooractivitiesAssembletheTPMTeamMaintenancepersonnelOperators

FirstlinesupervisionProvidenecessaryequipmentHelpteamdiagnoseabnormalitiesAssistskilledtradesCollectcopiesofdefecttagsan

dgenerateaworklistProvidepeopleresourcesTotalProductiveMaintenance(TPM)倡导者/发起人的角色一旦完成现场工作,接下来将:形成工作任务并跟踪其完成情况协助建

立和引入正确的定期维护明细表协助维持改善结果评估设备综合利用率OEE展示TPM的改善的成就TotalProductiveMaintenance(TPM)Champion/SponsorRoleUponCompletionofOnFloorEventGen

erateandtrackcompletionofworkordersAssistincreationandpostingofaccuratePeriodicMaintenanceListAssistinsustainingthegainsEva

luateOverallEquipmentEffectivenessDisplayTPMimprovementsTotalProductiveMaintenance(TPM)现场主管的角色指导并推广TPM概念监控现场的设备管理,保养及机器清洁工作的进行激发操

作员的主人翁意识对操作员授权为TPM活动提供时间方面的准备促进生产与维护双方的合作TotalProductiveMaintenance(TPM)Supervisor’sRoleCoachand

promoteTPMConceptsMonitorongoinghousekeepingandmachinecleanlinessPromoteOperatorownershipEmpowerOperat

orsProvidetimeforTPMactivitiesPromotecooperationbetweenProductionandMaintenanceTotalProductiveMaintenance(TPM)维护人员的角色“专业的管理者”有计划的实施所有的定期保养并

根据需要采取维修措施;使用振动分析,磨损度分析,热感应等预测工具;建立维护设备的保养记录与操作员协同工作并提供技术支持执行设备大修,综合调试负责执行一些特殊技能的任务,风险安全性高的作业促进TPMTotalProductiveMaintenance(TP

M)MaintenanceRole“TheSpecializedCaretakers”PerformallplannedpreventativemaintenanceandtakecorrectiveactionasneededUsepredicti

vetoolssuchasvibrationanalysis,wearparticleanalysis,andthermographyDocumentequipmentmaintenancehistoryCooperatewithOperatorsand

providetechnicalassistancePerformequipmentoverhaul,complexadjustmentsProvidespecialskilltasks,highsafety

risktasksPromoteTPMTotalProductiveMaintenance(TPM)操作员角色“一线管理者”清洁和缺陷检查执行基本的润滑,多点检测的工作按照核准清单的项目进行定期保养按计划执行日常清洁和整理识别刚刚发生的设备异常根据需要协助维护人员进行

维修执行基本的调试工作改善提案促进TPMTotalProductiveMaintenance(TPM)Operator’sRole“TheFirstLineCaretaker”Cleanandinsp

ectfordefectsPerformbasiclubrication,multi-pointinspectionPerformPeriodicMaintenanceperapprovedListPerformroutinecl

eaningandhousekeepingasscheduledIdentifyequipmentdefectsastheyariseAssistMaintenancewithrepairsuponrequestPerformbasica

djustmentsSuggestimprovementsPromoteTPMTotalProductiveMaintenance(TPM)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TotalProductiveMaintenance(TPM)The7StepsofTotalPro

ductiveMaintenance1.Performinitialmachinecleaningandinspection2.Identifyandtagmachinedefectsandleaks3.DevelopOperatorandM

aintenancePM’s4.InstructOperatorsinproperPMtechniques5.InstructMaintenanceStaffinproperPMtechniques6.Implement5SHousekeepingandOrganization7

.MonitorOEEandencouragecooperationTotalProductiveMaintenance(TPM)TPM安全常识遵守/使用停工现场标牌警示程序正确的起重方法用电安全操作规范劳保装备手套工作鞋护目镜

防尘口罩耳塞TotalProductiveMaintenance(TPM)TPMSafetyHabitsFollow/UseLockoutTagoutProcedureProperLiftingTec

hniquesElectricalSafetyGuidelinesPersonalProtectiveEquipmentGlovesSafetyShoesGogglesRespiratorsHearingProtectionTotalProductiveMaintenance

(TPM)TPM步骤1初始的机器清洁和检查目的:识别需修理处并标示缺陷执行:彻底清洁机器----团队所有成员参与并将所有需要维修的项目标示并记录TotalProductiveMaintenance(TPM)TPMStep1InitialMachineInspectionP

urpose:ToIdentifyneededrepairsandtagdefectsExecution:Cleanmachinethoroughly–donebyallteammembersTagandrecordallrepairsneededinaprojectnotebo

okTotalProductiveMaintenance(TPM)TPM步骤1“现场活动”彻底的清洁工作包括:清除所有的碎屑及其他残余物彻底地去除油污调节压缩空气更换过滤器,润滑剂等润滑移动部件及接头处清理不必要的使用工具,五金器具及备件

等“你的双手肯定会脏兮兮的!”TotalProductiveMaintenance(TPM)TPMStep1“OnFloorActivities”AThoroughCleaningIncludes:Removingallch

ipsandotherdebrisThoroughDegreasingCompressedairforcontrolsChangingfilters,lubricants,etc.LubricatingmovingpartsandjointsRemovingunnecessary

tooling,hardware,supplies,etc.“Youhavetogetyourhandsdirty!”TotalProductiveMaintenance(TPM)TPM步骤1“现场活动”维修项标示色码标签上须标示的信息:机器的资产编号机器位置及故障位

置投入使用的日期及使用人机油泄漏—橙色冷却液泄漏—绿色空气泄漏–黄色机器故障–粉红色电气问题--蓝色TotalProductiveMaintenance(TPM)TPMStep1“OnFloorActivities”Repai

rTagColorCodesInformationNeededonTagsAssetnumberofmachineLocationandrelativepositionofdefectonmachineNameoforigin

atoranddateOilLeaks-OrangeCoolantLeaks-GreenAirLeaks-YellowMachineDefects-PinkElectricalProblem

s-BlueTotalProductiveMaintenance(TPM)关注TPM清洁效果降低停机时间>70%之前–砂粒及碎屑很严重无法调试运行速度降低故障接连发生之后–跨功能工作的成果更换缺损的零部件调试校正恢复至设计速度且保持品质TotalProduct

iveMaintenance(TPM)FocusedTPMCleaningEffortReducedDowntimeby>70%Before–SevereGritandChipsOutofadjustmentsRunningatr

educedspeedsConstantbreakdownsAfter–Cross-functionalEffortReplacedbrokenandmissingpartsCorrectedtheadjustmentReturnedto

designedspeedwithoutincurringTotalProductiveMaintenance(TPM)TPM步骤2修复机器的缺漏目的:修复在步骤1中找到的缺漏项目注意事项:倡导者/发起人需确保标示出的问题得到修复实际的修复工作不必一定由团队成员来做;生产主管须确保机器

能够使用TotalProductiveMaintenance(TPM)TPMStep2RepairmachinedefectsandleaksPurpose:TorepairitemsfoundinStep1Considerations:Champion/Sponsorinsur

estaggedproblemsarerepairedActualrepairsdonothavetobedonebyteammembersProductionSupervisorhastomakemachineavailableTota

lProductiveMaintenance(TPM)TPM步骤2消除故障因素固定并拧紧所有的扣件,接头,螺钉及螺母替换任何缺损的部件替换任何损坏,磨损及规格不符的零部件解决所有的渗漏,溢出,喷溅,噪杂等问题提高如下环节的可操作性:清洁润滑调试

检查/测试TotalProductiveMaintenance(TPM)TPMStep2Eliminatefactorscontributingtofailure:Secureandtightenallfasteners,fittings,boltsan

dscrewsReplaceanymissingpartsReplaceanydamaged,wornorwrongsizepartsResolveallcausesofleaks,spillage,sprayandsplatterImp

roveaccessibilityinordertoaccomplish:CleaningLubricatingAdjustingChecking/inspectingTotalProductiveMaintenance(TPM)TPM步骤3建立操作员和维护人员合作的PM计划确保发出完善

的定期检测的查检表目的:注意事项:由TPM项目小组建立PM计划谁来执行任务任务执行的频率(例如每天,每周等)TotalProductiveMaintenance(TPM)TPMStep3DevelopOperatorPM’sandMaintenancePM’sPurpose:Toinsu

readequatepreventativemaintenancechecklistsarepostedConsiderations:TPMProjectTeamtodevelopPM’sWhoistoperformtasksFrequencyoftas

ks(i.e.,daily,weekly,etc.)TotalProductiveMaintenance(TPM)TPM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注意事项:操作员负责按照管理文件执行PM工作;生产主管须确

保PM工作的有效实施TotalProductiveMaintenance(TPM)TPMStep4PMactivityperformedbytheOperatorPurpose:Todetectearlyproblems,providethese

rviceinterval,andinsure5SprocedureisfollowedConsiderations:OperatorisresponsibletoperformPM’sasdocum

entedProductionSupervisortoinsurePM’sareeffectiveTotalProductiveMaintenance(TPM)TPMTPM使操作员更加独立地自我管理和控制;操作员时时关注小问题的发生就有可能:迅速地发现潜在的问题修正现有问题

确定状态正常良好地维持设备整体状况TotalProductiveMaintenance(TPM)TPMTPMmakestheoperatormoreindependentTheoperatorseesthesmallpro

blemsnowwiththepossibilityof:QuicklynotingpotentialproblemsCorrectingthecurrentsituationRecognizingn

ormalconditionsMaintainingthemachineingoodoverallconditionTotalProductiveMaintenance(TPM)自主维护管理指的是操作员参与自己所操作的

设备的维护作业怎样使操作员更加自主,实现自我管理:利用文件管理明确维护/生产作业的规定明确操作员如何进行日常检测进行基本的操作,维护及故障检测的培训使日常作业直观,一目了然明确识别须监督管理的项目Tot

alProductiveMaintenance(TPM)AutonomousMaintenanceReferstoactivitiesinvolvingoperatorsinthemaintenanceoftheirownequipmentHowtomaketheop

eratormoreindependent:MakedocumentationavailableDefinemaintenance/manufacturingactivitiesShowoperatorhowtoperf

ormdailychecksTraininbasicoperation,maintenance,anddefectdetectionMakedailyactivitiesvisibleClearlyidentifyitemstosuperviseTotalProductiveMai

ntenance(TPM)落实自主维护管理确定过程实施中的关键机器及设备执行初步清洁工作清除脏污及污染源建立清洁和润滑标准就设备的保养需求对操作员进行培训贯彻实施一个综合性的维护系统对保养效果进行定期审查TotalProductiveMaintenance(TPM)Autono

mousMaintenanceImplementationIdentifyprocesscriticalmachineryandequipmentPerforminitialcleaningResolveso

urcesofdirtandcontaminationCreatecleaningandlubricationstandardsTrainoperatorsonequipmentmaintenancerequirementsImplementacomp

rehensivemaintenancesystemEstablishperiodicauditsofmaintenanceeffectivenessTotalProductiveMaintenance(TPM)为什么清洁?不恰

当的清洁所带来的负面影响:故障产品缺陷加快设备磨损产量降低设备磨损正常磨损:尽管正确操作仍然会发生加快磨损:由于误操作及疏忽于保养导致加快磨损TotalProductiveMaintenance(TPM)Wh

yClean?AdverseeffectsofinadequatecleaningFailureProductdefectsAccelerateddeteriorationThroughputlossEquipmentdeteriorationNormaldeterioratio

n:occursdespitecorrectuseAccelerateddeterioration:quickerdeteriorationoccurringduetomisuseinoperationandne

glectofmaintenanceTotalProductiveMaintenance(TPM)清洁可作为磨损检查清洁可减缓磨损速度接触设备可发现异常情况采取保养措施可延长使用寿命,避除故障TotalProductiveMai

ntenance(TPM)CleaningasDetectionofDeteriorationCleaningreducesaccelerateddeteriorationPhysicalcontactw

ithequipmentexposesabnormaloperationconditionsPreventiveactiontakenextendsusefullifeandavoidsbreakdownsTotalProductiveMaintenance(TPM)常见的设备缺陷

断线软管磨破漏油漏气散热剂泄漏托架损坏电线裸露多余及废弃的器具防护装置损坏或不见TotalProductiveMaintenance(TPM)TypicalDefectsFoundBrokenflexWornhosesO

illeaksAirLeaksCoolantleaksBrokenBracketsFrayedwiresUnnecessaryandobsoletetoolingDamagedormissingguardsTotalProductiveMaintenance(T

PM)设备故障专家估计与移动装置相关的机器故障有60%是由于缺乏或不适当的润滑导致的;建立设备故障资料库收集并管理故障资料分析故障趋势及形式定期展开和发布总结报告包括用于定期回顾之用的会议议程报告TotalProductiveMaintenance(TPM)EquipmentF

ailuresExpertsestimatethat60%ofmachinebreakdownsassociatedwithmovingpartsareduetolackoforimproperlubricationpractices.Establishanequipmentfa

iluredatabaseGatherandmanagefailureinformationAnalyzefortrendsandpatternsDevelopandissueperiodicsummaryreportsIncludereportsasame

etingagendaforregularreviewTotalProductiveMaintenance(TPM)TPM步骤4(续）目视管理张贴设备润滑工作示意图标示油位玻璃管的上下线所有的气管,水管,油管及冷却剂管区分标

示张贴OEE的图表分析公布本年度截至目前为止的保养成本公布5S审查的得分情况TotalProductiveMaintenance(TPM)TPMStep4（Con.)VisualsControls

LubricationplacardsinplaceUpperandlowersightglassesinplaceAllair,water,gas,andcoolantlinesarelabeledOEEposted

YTDMaintenancecostsposted5SAuditScorespostedTotalProductiveMaintenance(TPM)TPM步骤5由维护人员执行的PM作业目的:预防机器故障---在发生故障之前解决注意事项:PM作业内容由维修及生产人员共同订立保

全主管须确保PM作业的有效性TotalProductiveMaintenance(TPM)TPMStep5PMactivityperformedbyMaintenancePersonnelPurpose:T

opreventmachinefailure-fixbeforefailureConsiderations:PM’sarescheduledjointlybyMaintenanceandProductionMaintenanceSupervisortoinsurePM’

sareeffectiveTotalProductiveMaintenance(TPM)TPM步骤6贯彻5S现场管理及组织体系确保维持清洁成果及团队执行:整理清理掉无用的及已经损坏的东西整顿要用的东西依规定

定位,明确标示清洁清除脏污,防止污染,保持从上到下的清洁标准化规范保养频次素养长期改善,养成好习惯TotalProductiveMaintenance(TPM)TPMStep6Implement5SHousekeepingandOrganizationPurpose:Toensu

redsustainedcleanlinessandorganizationExecution:SortRemoveobsoleteandbrokenequipmentSetInOrderEverythinginadesig

natedplaceShineToptobottomcleaningStandardizeAllowtimeandmaintainfrequencySustainLongtermimprovementTotalProductiveMaintenance(TPM)TP

M步骤7监控设备综合利用率OEE,鼓励合作目的:不断总结并改善机器的性能并加强维修和生产部门的合作注意事项:需要定期进行TPM工作总结追踪现行的活动进度状况确定下一个需改善的区域需要时采取校正措施T

otalProductiveMaintenance(TPM)TPMStep7MonitorOEEandencouragecooperationPurpose:Tocontinuouslyreview

andimprovemachineperformanceandcooperationbetweenMaintenanceandProductionConsiderations:Haveregularlyscheduled

TPMreviewsTrackprogressofongoingactivitiesIdentifyareasforfutureimprovementsInitiatecorrectiveactionwhenneededTotalProductiveMaintenance(TPM

)TPM步骤7TPM衡量指标对任一过程,衡量指标都能既监控过程性能又表现TPM效果设备的利用率(OEE)可用水平AL作业水平OL质量水平QL设备综合利用率OEE故障平均间隔时间(MTBF)维修平均间隔时间(MTTR)TotalProductiveMaintenance(TPM

)TPMStep7TPMMetricsAswithanyprocess,MetricsareneededtobothmonitorprocessperformanceandunderstandgainsmadefromtheTPMeffortOpe

rationEquipmentEffectiveness(OEE)AvailabilityLevelOperatingLevelQualityLevelOEEMeanTimeBetweenFailure(MTBF)MeanTime

ToRepair(MTTR)TotalProductiveMaintenance(TPM)知识获取重点一个完善的TPM程序可以:加快对客户反应速度减少机器停工时间改善品质增强工作安全性降低成本,提高利润建造愉快的工作氛围增进合作降低工业污染

降低库存水平TotalProductiveMaintenance(TPM)TakeawaysAsolidTPMprogramresultsin:ImprovedresponsetimetocustomerReducedmachinedowntimeImprovedqualityIncr

easedjobsafetyReducecostandincreasedprofitsProvidesapleasantworkingatmosphereImprovedlevelsofcooperationReducedindustrialpoll

utionReducedinventorylevelsTotalProductiveMaintenance(TPM)