【正文】 TPM Continuous Improvement (CI) Handbook Rev B 持續(xù)改進(jìn) CI支柱 CONTINUOUS IMPROVEMENT PILLAR 這根支柱首要的目的是在消除 16種主要損失中查明 /找到問(wèn)題的根本原因 The primary aim of this pillar is to determine the root cause of the problem in eliminating the 16 major losses 目標(biāo) Objective : 用 9步主要的標(biāo)準(zhǔn)體系通過(guò)靠近 0損失的方式來(lái)指引 CI活動(dòng)達(dá)到消除 16種損失的目標(biāo) Lead CI activities to eliminate 16 losses associated with 9 key metrics through Zero Loss approach. 范圍 Scope : 應(yīng)用到 13種主要的 package(專(zhuān)注于模板團(tuán)隊(duì)） Applies to 13 key packages (Focus on Model teams). 主要達(dá)到的途徑 Key Deliverables : 首要的目標(biāo)：達(dá)到 9步主要的標(biāo)準(zhǔn)體系 通過(guò) 0損失的造詣實(shí)現(xiàn)連續(xù)性的專(zhuān)注的次數(shù) Primary Goals: Meet 9 key metrics. of Permanent Fixes through Zero Loss acplishments. 第二目標(biāo)：為什么為什么分析專(zhuān)家的次數(shù) PM分析專(zhuān)家的次數(shù) Secondary Goals: of WhyWhy Analysis Expert. of PM Analysis Expert. 增加有價(jià)值的 CI CI ValuedAdded: ? 引導(dǎo)全廠的 CI活動(dòng)和最大化地利用有效地資源向著 9步主要標(biāo)準(zhǔn)體系邁進(jìn) Steers plantwide CI activities and maximize effective use of resources towards achieving 9 key metrics. ? 通過(guò) TPM活動(dòng)為了主要的項(xiàng)目拉動(dòng)所有的資源 Pull resources for key projects through TPM Plant / Departmental SC. ? 標(biāo)準(zhǔn)化使用過(guò)的工具和方法 Standardize Tools and methodologies used. CI 支柱的綱領(lǐng) CI支柱的要求 CI PILLAR APPROACH ? 識(shí)別 /辨別 16種損失和質(zhì)量事件 Identify 16 losses and Quality issues ? 定量 /排序損失和質(zhì)量 Quantify / Prioritize losses and Quality ? 藏寶圖 /流程圖 Treasure Map ? 聯(lián)接項(xiàng)目到標(biāo)準(zhǔn)體系（定義測(cè)量到具體數(shù)據(jù)） Link projects to metrics (define measurements to metric) ? 在模板設(shè)備上優(yōu)化項(xiàng)目或者關(guān)心質(zhì)量事件 Prioritize projects on model equipment (8 equip. or 5 manpower losses) or with respect to Quality issues ? 查閱 /指導(dǎo) /引導(dǎo) Consult/ Guide / Lead ? 標(biāo)準(zhǔn)化解決問(wèn)題的工具和方法 Standardize problem solving tools amp。 methodologies ? 協(xié)同運(yùn)作 AM / PM/ QM 支柱 Collaboration with AM/ PM/ QM Pillar ? 提供 WhyWhy和 PM分析的培訓(xùn) Provide Training on WhyWhy and PM Analysis ? 回顧項(xiàng)目的進(jìn)展 Review project progress ? 回顧影響到具體的數(shù)據(jù) Review impact to metrics APS損失 APS losses CI項(xiàng)目 CI projects 工廠標(biāo)準(zhǔn)化體系 Plant metrics APS TPM TRAINING PROCESS 心臟 Heart Feelings/ Passion (Values Training) 手 Hands (AM Workshop) 腿 Legs (Cascading Small Group Activity) 腦 Brain (Burning Platform) Understand the Business World Understanding why past success carry the seed of Failure 心 Mind (Introduction to TPM ) Understanding TPM Collaboration for a Common Goal ! E .H. S. Continuous Improvement Autonomous Maintenance Planned Maintenance Training amp。 Education Initial Flow Control Quality Maintenance Office TPM TPM 8 PILLAR 完整的 5S管理新行動(dòng) 基石 CI的范圍 SCOPE OF . . Tamp。E . . . 16 losses 在消除 16種主要損失的過(guò)程中 CI活動(dòng)圍繞著 TPM的所有 8支柱之中 Continuous Improvement activities enpass all the 8 TPM pillars in eliminating the 16 Major Losses. IFC EHS OTPM 關(guān)于 AM/PM/CI活動(dòng)失效的分類(lèi) Classification of Failures for AM/PM/CI Activities. Responsibility Locations where failures occur Causes of failures 70 % of Failures that can be prevented through . 70%的失效能夠通過(guò) AM 預(yù)防 探測(cè)器 /傳感器 Detector/sensor 驅(qū)動(dòng)系統(tǒng) Driving system 潤(rùn)滑系統(tǒng) Lubricating system 螺栓和螺母 Bolts and nuts 氣動(dòng)系統(tǒng) Pneumatics 工具 /夾具 Jigs/tools 電子系統(tǒng) Electric systems 電子電器設(shè)備 Electric/electronic equipment 原狀態(tài)不能實(shí)現(xiàn) Original conditions are not materialized 變化變質(zhì) Leaving deterioration unattended (No AM activity) 技能缺乏 Shortage of skills 操作條件的無(wú)可視化 Nonobservance study of operating conditions 30% of remaining Failures that cannot be solved except through . amp。 . 除了通過(guò) PM和 CI,30%的 失效不能夠被解決 電子電器設(shè)備 Electric/electronic equipment 驅(qū)動(dòng)系統(tǒng) Driving system 液壓系統(tǒng) Hydraulic system 電子和氣壓系統(tǒng) Electric and air pressure systems 探測(cè)器 /工具 /夾具 Detectors/jigs/tools 老化變質(zhì) Leaving deterioration unrectified 內(nèi)部設(shè)計(jì)缺陷 Inherent design shortings 技能缺乏 Shortage of skills 基本的操作條件沒(méi)有被保持 Basic and operating conditions are not kept 潤(rùn)滑系統(tǒng) Lubricating system Maintenance Manufacturing * Planned Maintenance Activities *AM Activity Periodic Maintenance 周期的維護(hù) Correct Operation 8 equipment amp。 5 manpower Predictive Maintenance預(yù)測(cè)性的維護(hù) Oiling Inspection losses amp。 Zero Defects Corrective Maintenance Cleaning Dust free root cause “Breakdown Maintenance Activities” Tightening 緊固 analysis 無(wú)塵的 AM data analysis One stop defect free Restoring 恢復(fù)性的 changeover 一站式減少缺陷的轉(zhuǎn)換 Fan In / Fan Out dealing with ... Minor Stoppages Speed Loss Specification Review/Write ups詳細(xì)描寫(xiě) Zero Defect AM /PM/ Tamp。E /QM的相互關(guān)系 Collaboration with AM /PM/ Tamp。E /QM PM Pillar AM Pillar CI/QM Pillar 為了 CI的團(tuán)隊(duì)精神，通過(guò)每件信息的 OPL加強(qiáng) for Continuous Team spirit Enhancement through OPL of Every Information Tamp。E Pillar Phase 3 通過(guò)經(jīng)常糾正變質(zhì)來(lái)恢復(fù) Restoration by correcting deterioration regularly 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) Step 6 維修效率的改善 Efficiency improvement of maintenance 朝著 0失效的 4階段 4 Phases Towards Zero Failures Phase 1 提高 MTBF Improving Mean Time Between Failure (MTBF). Step 1. 清理過(guò)去的失效 Sorting out of past failures Step 2. 失效分析和全面的檢查 Failure analysis and overall inspection 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 Phase 2