【正文】 ? Generally does not perform any maintenance activities ? Contacts maintenance when a machine breakdown occurs ? Inactive during maintenance activities ? “Run it 39。till it breaks” Control Total Productive Maintenance (TPM) 15 主要概念 定期保養(yǎng)是一種基于時間長短或使用狀況對設(shè)備進行檢修的方法 .在指定時間或在使用空檔間對設(shè)備實施檢修作業(yè)以防止設(shè)備發(fā)生故障 . ? 定期保養(yǎng)計劃 預(yù)測性保養(yǎng)是一種基于設(shè)備狀態(tài)的維護方法 .根據(jù)可視信號或檢測技術(shù)的情況來實施保養(yǎng)以防止設(shè)備發(fā)生故障 . ? 振動分析 ? 激光探測 ? 超聲波檢測 ? 發(fā)電機測試 ? 熱感應(yīng) ? 油況分析 預(yù)測性保養(yǎng) 定期保養(yǎng) 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 occurring. ? PM 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. ? Vibration Analysis ? Laser Measuring ? Ultrasound ? Generator Testing ? Thermography ? Oil Analysis Predictive Maintenance Preventive Maintenance Control Total Productive Maintenance (TPM) 17 現(xiàn)狀分析和團隊組織 ? 評估當(dāng)前的操作條件 : ? 機器利用率 ,生產(chǎn)率等 。 ? 維修費用 (配件和人工 ) ? 對實現(xiàn) TPM的各項工作進行優(yōu)先次序 ? 評估潛在 TPM倡導(dǎo)者及團隊成員的實力 ? 挑選 TPM倡導(dǎo)者及團隊成員 ? 建立初始的實施專門小組 ? 確定團隊目標(biāo) Control Total Productive Maintenance (TPM) 18 Present State Analysis and Team Organization ? Assess Current Operating Conditions ? Machine utilization, productivity, etc. ? Maintenance repair costs (parts and labor) ? Prioritize order of TPM efforts ? Assess capabilities of potential TPM Champions and Team Members ? Select TPM Champion and Team Members ? Establish initial kickoff workshop ? Establish team goal Control Total Productive Maintenance (TPM) 19 典型的設(shè)備評價指標(biāo) ? 利用率 : 設(shè)備實際運轉(zhuǎn)時間與總的可利用時間的比率 。 ? = 實際運行時間 /可運行時間 ? 效率 : 實際產(chǎn)量與標(biāo)準(zhǔn)產(chǎn)量的比率 ? = (實際產(chǎn)量 /小時 )/(標(biāo)準(zhǔn)產(chǎn)量 /小時 ) ? 產(chǎn)出 : 用一特定時間段的產(chǎn)量來衡量 ? = 磅 /小時 , 件數(shù) /小時 Control Total Productive Maintenance (TPM) 20 Typical Operational Process Measurements ? Utilization: The ratio of equipment actual operating time to the total available operating time ? = Actual Operating Time/Available Time ? Efficiency: The ratio of actual product produced to a standard ? = (Actual Parts/Hour)/(Standard Part/Hour) ? Output: Measure of output over a specified time period ? = lbs/hr, pieces/hr Control Total Productive Maintenance (TPM) 21 設(shè)備綜合利用率 OEE ? 設(shè)備綜合利用率（ OEE） 是衡量一臺設(shè)備按計劃速度生產(chǎn)出合格產(chǎn)品的時間占全部時間的百分比 . Control Total Productive Maintenance (TPM) 22 Overall Equipment Effectiveness ? Overall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality product at the designed rate. Control Total Productive Maintenance (TPM) 23 OEE分解 :六大浪費 故障及輕微故障 使設(shè)備中斷運行的時間超過 10分鐘的故障或者中斷時間少于 10分鐘的輕微故障 . 設(shè)置時間浪費 任何與設(shè)備調(diào)整 ,裝配 ,清潔相關(guān)的作業(yè) . 機器空轉(zhuǎn)浪費 設(shè)備在運轉(zhuǎn)卻沒有用來生產(chǎn)產(chǎn)品所耗用的時間 . 速度浪費 由于設(shè)備或產(chǎn)品的異常造成設(shè)備以低于標(biāo)準(zhǔn)速度或所設(shè)定的速度運轉(zhuǎn) . 品質(zhì)原因浪費 為確保設(shè)備產(chǎn)出品的品質(zhì)而采取相關(guān)的作業(yè) (過程中檢查 ). 返工浪費 用于返修產(chǎn)品或生產(chǎn)出報廢產(chǎn)品所耗用的時間 . 可用水平 (AL) 運行水平 (OL) 質(zhì)量水平 (QL) 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 equipment 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 equipment (inprocess checks). Rework Losses The time taken to reprocess product or time take to produce unusable product. Availability Level (AL) Operating Level (OL) Quality Level (QL) Control Total Productive Maintenance (TPM) 25 六大浪費的識別練習(xí) 識別損失類別12345678910機器A 在下午1 點鐘完成一產(chǎn)品裝配而在下午2 : 2 7 開始另一產(chǎn)品的裝配工作現(xiàn)象由于電氣故障機器A 的運轉(zhuǎn)中斷3 1 分鐘過程中的質(zhì)量檢查耗時2 2 分鐘機器B 上的小裝置裝卸時間為4 分鐘由于機械故障機器X 運轉(zhuǎn)中斷8 分鐘機器Z 的清潔時間為4 7 分鐘工件被軋住造成機器C 中斷3 分鐘從取樣到送至實驗室耗時3 2 分鐘機器Z 返修2 0 0 個工件由于機油線路泄漏機器D 僅能以每小時加工1 0 0 片產(chǎn)品的速度運行達不到1 2 5 片的標(biāo)準(zhǔn) S C E N A R I O L O S S I D E N T I F I C A T I O N 1. M a c h i n e A o p e r a t i o n i s i n t e r r u p t e d b y a n e l e c t r i c a l p r o b l e m f o r 3 1 m i n u t e s 由于電氣故障機器 A 的運轉(zhuǎn)中斷 31 分鐘 2. A n i n p r o c e s s q u a l i t y c h e c k t a k e s 2 2 m i n u t e s 3. L o a d u n l o a d t i m e b e t w e e n w i d g e t s o n m a c h i n e B i s 4 m i n u t e s 機器 B 上的小部件 裝卸的時 間 為 4 分鐘 4. M a c h i n e X o p e r a t i o n i s i n t e r r u p t e d o f 8 m i n u t e s d u e t o a m e c h a n i c a l p r o b l e m 由于機械故障機器 X 運轉(zhuǎn)中斷 8 分鐘 5. C l e a n i n g t i m e o n m a c h i n e Z i s 4 7 m i n u t e s 機器 Z 的清潔時間為47 分鐘 6. J a m m e d p i e c e c a u s e s m a c h i n e C s t o p p a g e o f 3 m i n u t e s 7. M a c h i n e A c o m p l e t e s a l o a d a t 1 : 0 0 p m a n d b e g i n s a n o t h e r l o a d ( d i f f e r e n t p r o d u c t ) a t 2 : 2 7 p m 8. A s a m p l e i s t a k e n a n d t r a n s p o r t e d t o t h e l a b t a k i n g 3 2 m i n u t e s 9. 2 0 0 p i e c e s a r e r e p r o c e s s e d o n m a c h i n e Z 10. M a c h i n e D r u n s a t 1 0 0 p c / h r n o t 1 2 5 p c / h r d u e t o l e a k y o i l l i n e s Control Total Productive Maintenance (TPM) 26 Six Big Losses Identification Exercise S C E N A R I O L O S S I D E N T I F I C A T I O N 1. Mach