【正文】 Total Productive Maintenance Manufacturing 生產(chǎn)部門 1 Process Certification TPM QCPC Root Cause / Corrective Action SetUp Reduction Standard Work Mistake Proofing Market Feedback Analysis 6S Quality Clinic Activity Total Productive Maintenance ACE Manufacturing Qualifying Level 2 程序驗證 全面性生產(chǎn) 維護 質(zhì)量診斷程序 圖表 根本原因 修正行動 減少生產(chǎn) 準備 標準化 作業(yè) 防誤措施 市場反饋 分析 6S 質(zhì)量診斷 行動 全面生產(chǎn)性維護 ACE 生產(chǎn)部門合格水平 3 Total Productive Maintenance is an equipment management strategy that improves equipment efficiency. 全面生產(chǎn)性維護是一種設備管理策略以提高設備效率。 Or, in other words... Treating the equipment like it is your own! 或者，換句話說 ……. 對待設備就象它是你自己的 一樣！ TPM 全面生產(chǎn)性維護 4 TPM Key Concept TPM的重要概念 ? Left neglected... Equipment Breaks Down ? 如果不重視 … 設備很快就會壞 TPM’s focus is to prevent problems before equipment breaks. TPM 的焦點是要在設備出故障 以前 防止問題出現(xiàn)。 In the past, maintenance focused on fixing equipment after it broke. 過去，維護工作總是集中在設備壞了 以后 對其進行修理。 5 Total Productive Maintenance is a New Way of Working 全面生產(chǎn)性維護是一種全新的工作方式 TPM Attitude: TPM態(tài)度： “We are all responsible for our equipment.” “我們所有人對我們的設備負責?！? Old Attitude: 過去的態(tài)度： “I operate, you fix.” “我操作，你修理?！? “I fix, you design.” “我處理，你設計?！? “I design, you operate.” “我設計，你操作?！? 6 Hidden Defects 隱藏的問題 Failures 故障 Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw materials,surface damage, cracking, overheating, vibration, noise, and other abnormalities. 磨損、松馳、泄露、灰塵、污垢、腐蝕變形、原材料粘黏、表面磨損、裂縫、過熱、震動、噪音及其它不正常現(xiàn)象。 Tip of the Iceberg 冰山的頂端 7 Typical Causes of Machine Breakdown 典型的機械故障原因 Failure to add oil. 沒有加油 Grit and chips in revolving or sliding parts 旋轉(zhuǎn)或滑動零件中的砂礫和碎片 Contamination of sensors, contacts and Connectors 傳感器、觸敏器、 連接器污染 Dirt and dust on cooling fan 冷卻風扇上有 灰塵和污垢 Component Failure 組件失靈 I wonder what’s going to fail next? 我在想下面還會出什么 問題呢？ 8 TPM Techniques TPM技術(shù) Normal operating Range 正常操作范圍 Danger! 危險！ ? Simplify and Document TPM Activities. ? 簡化并記錄 TPM行動 ? Use visual techniques to indicate what’s right / what’s wrong. ? 運用直觀技術(shù)來演示什么是 對的 /什么是錯的。 – PM Completed? 生產(chǎn)性維護完成了嗎？ – Pressure gage 壓力計 – Sight glass 視鏡 – Arrows for motor rotation and fluid circulation馬達旋轉(zhuǎn)和潤油指示箭頭 – markings for spare parts and fluids. – 備用零件和潤滑油記號 Making PM devices more accessible. ? 使生產(chǎn)性維護設備更容易獲得 – Filters, fittings made more accessible 過濾器、各種裝置 – Transparent panels to facilitate inspection 明了易讀的儀表盤便于檢查 9 TPM Benefits TPM的益處 ? Reduced maintenance costs ? 減少維護費用 – Breakdown maintenance is 10 times more costly than planned maintenance – 故障維修費用是有計劃進行維護費用的 10倍以上 ? Enhanced safety 提高安全性 – Find exposed wires, open belts, missing guards, loose hardware – 發(fā)現(xiàn)暴露在外的電線、松開的安全帶、缺少防護、松開的部件 ? Reduced waste 減少浪費 – Prevents loss of lubricant, pressed air – 防止?jié)櫥?、壓縮空氣的浪費 ? Improved quality 提高品質(zhì) – Equipment more capable of holding tolerance – 設備抗性增強 ? Less down time, longer life縮短停工時間，壽命更長 10 12 TPM Qualifying Activities ? ACE Element Awareness Training ? Lock Out/Tag Out awareness training available for all employees (with annual refresher) ? Operators of high hazard equipment informed of machine specific hazards