【正文】 擴(kuò)展內(nèi)部的服務(wù)壽命 Extending the inherent service life Phase 4 預(yù)測服務(wù)壽命 Predicting the service life Step 7 預(yù)測維護(hù)的引進(jìn) Implementation of predictive maintenance Step 4 弱點(diǎn)的研究 Study of weak points 0失效的程序 Program for Zero Failures Step 1. 清理過去的失效 Sorting out of past failures * 分類整理經(jīng)常的和突然的失效 單個發(fā)生的 Classification of recurring or sudden failures sporadic * 以困難程度為基礎(chǔ)進(jìn)行分類整理 Classification based on difficulty (Is prevention possible based on autonomous maintenance?) * 以事件的一部分為基礎(chǔ)進(jìn)行分類整理 Classification based on occurrence portions * 以失效模式為基礎(chǔ)進(jìn)行分類整理 Classification based on failure modes [Role of AM] * Identify responsibility attributable to the manufacturing sector, regarding misoperation, and taking steps (education and foolproofing) OPL amp。 Trend Charts * How to handle, in the future, failures that can be dealt with AM [Role of PM] * Identifying recurring failures based on maintenance records Data Trend Chart * Perform permanent fixing of failures which have been dealt with by quick fix OPL’s. Step 2. 失效分析和全面的檢查 Failure analysis and overall inspection * 重新分析經(jīng)常性發(fā)生的失效 Reanalysis of recurrent failures * 新的失效的全面分析 Thorough analysis of new failures [Role of AM] * Analyzing failures considering that they are problems of the manufacturing sector * Repeating whywhy analysis * Inspection of analogous facilities and correction of causes [Role of PM] * Thorough analysis and guidance to AM Activity * Confirmation and correction of repair errors (skill education/training, etc.) 0失效的程序 Program for Zero Failures Cont Step 3. 強(qiáng)力的變質(zhì)的消除和不用照顧的變質(zhì)的糾正 Elimination of forced deterioration and rectification of unattended deterioration [Role of AM] * 通過清潔尋找最小化的缺陷 Finding minor defects through cleaning * 基本條件的改善 Improvement of basic conditions (Elimination of forced deterioration caused by dirt, suitable oiling, tightening) * Studying use conditions [Role of PM] * Educational guidance regarding minor defects * 使用條件的分類和指導(dǎo) Classification and guidance of use conditions * 消除看不見的強(qiáng)力變質(zhì) Elimination of forced deterioration in unseen portions * 早點(diǎn)被辨認(rèn)的 /識別的變質(zhì)的糾正 Early rectification of deterioration that have been identified Step 4. 弱點(diǎn)的研究 Study of weak points [Role of AM] *引進(jìn)改善以至于基本條件的維護(hù)將變得更容易 Implementing improvements so that the maintenance of basic conditions will be easier (countermeasures for contamination sources, for hardtoaccess areas) [Role of PM] * 清理和糾正設(shè)計(jì)缺陷 Sorting out and correcting design weak points * 延長壽命的研究 Study of steps for extending service life * 結(jié)構(gòu)的改善 Structural improvement Step 5. 標(biāo)準(zhǔn)化文件的準(zhǔn)備和控制 Preparation and control of standard documents (including failures involving defects) [Role of AM] * AM標(biāo)準(zhǔn)文件的準(zhǔn)備 Preparation of AM standard documents * 以檢查和變質(zhì)的糾正清單 Check listbased inspection and rectification of deterioration * 通過總體設(shè)備的檢查來糾正和觀察故障 Inspection and correction of malfunctions through total equipment inspection [Role of PM] * 規(guī)則的維護(hù)和標(biāo)準(zhǔn)化文件的準(zhǔn)備 Preparation of regular maintenance standard documents (grasping the service life of individual equipment and ponent parts) and rectifying deterioration * 在設(shè)備精度和品質(zhì)特性之間的關(guān)系分類 Clarification of relations between equipment accuracy and quality characteristics 0失效的程序 Program for Zero Failures Cont Step 6. 維修效率的改善 Efficiency improvement of maintenance [[Role of AM] * 外觀控制的改善 Improvement of visual control [Role of PM] * 可維護(hù)性的改善 Improvement of maintainability (MTBF) Step 7. 預(yù)測維護(hù)的引進(jìn) Implementation of predictive maintenance [Role of AM] * 以簡單診斷設(shè)備和趨勢控制為基礎(chǔ)的條件監(jiān)控 Condition monitoring based on simple diagnostic equipment and trend control [Role of PM] * 通過精密的診斷設(shè)備和預(yù)測服務(wù)壽命來掌握變質(zhì) Grasping deterioration through precision diagnostic equipment and predicting service life 對于 CI持續(xù)改善來說，重復(fù)第 3步到第 7步 Repeat steps 3 to 7 for Continuous Improvement CI 流程 CI Process 選擇模板 設(shè)備 Selecting model equipment 項(xiàng)目團(tuán)隊(duì) Project team 辨認(rèn) 16種 主要的損失 Identify 16 major losses 確定主題，計(jì)劃和準(zhǔn)備 Deciding the theme*, planning and preparation 對于設(shè)備內(nèi)部 可靠性的改善 Improvement of reliability inherent to equipment Improvement of equipment efficiency ? Manager (leader) ? Production engineering ? Design ? Maintenance ? Others QA, ? 瓶頸流程 Bottleneck process ? 大量的損失 Large loss ? 比較大的橫向的反響因數(shù) Larger horizontal replication factor ? 對于設(shè)備，哪線、流程？ For equipment, line and process ? 和 AM機(jī)器匹配 Matching with AM model equipment 16種主要的損失 16 major losses (1) Failure loss (5) Minor stoppage amp。 idling loss (6) Speed loss (7) Defects amp。 rework loss (2) Setup amp。 adjustment loss (10) Operating motion loss (12) Logistic loss (3) Cutting blade amp。 jig change loss (8) Shut down (SD) loss (13) Measurement amp。 adjustment loss (14) Yield loss (9) Management loss (11) Line anization loss (4) Startup loss (15) Energy loss (16) Die amp。 jig loss 功能停止 Function stoppage 功能退化 /變質(zhì) Function deterioration 頻率縮小 Reduction in frequency Failure analysis technique WhyWhy PM analysis 設(shè)備使用可靠性的改善 Improvement of equipment usage reliability. 循環(huán)預(yù)防 Prevention of recurrence . 標(biāo)準(zhǔn)回顧 Standard review. ?Industrial Engineering ?QA ?Value Engineering ?Others AM system 橫向的反響 Horizontal replication PM system Office TPM CI項(xiàng)目活動 Continuous Improvement project activities *Theme selection standard ? Critical items ? Maximum gains ? Can