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O E E Lo ss E f f e c t s. 020406080100120% time available24/ 7 s c h e d u l e d t i m e A vai l i b i l i t y P e r f or m an c e ( E f f ) Y i e l d ( Q u al i t y)OEE Pareto Analysis by Loss Category Overall Equipment Effectiveness Loss 3 4 % OEE Loss 1 2 Loss 5 6 TPM attacks 6 major “Losses” plus Elimination of other Wastes (Mura, Muri, Muda) ? Operator Time Losses – Manpower losses due to operation time being done more slowly than standard time (Cycle Time Standard Time) ? Material Losses – Losses in yield due to ?inherent waste? (cutoff stock, setup pieces, prototype, etc) – Energy losses such as electricity, gas, and water when machinery is not doing valueadded work – Idling losses due to inadequate sensors and product buildup on conveyors and chutes Best Practices WorldClass Goals (A TPM “Vision”) Before After Availability 87% 90% Performance Efficiency 50% 95% Ratio of Quality (Yield) 98% 99% Overall Eq. Effectiveness % 85% TPM – Operational Goals (Qualitative) ? Increase number of suggestions ? Improve level of teamwork of shop floor ? Improve crossfunctional teamwork ? Establish maintenance throughout the total equipment life cycle ? People maintain their own equipment ? Machines available for justintime (JIT) application ? Improve machine availability ? Improve working environment (6S) ? Improve Corporate culture and image ? Improve Business performance TPM – Operational Goals (Quantitative) ? Cost Reductions – Actual and to be reduced – Energy savings – Maintenance ? Equipment Efficiencies – Zero failures (ultimate goal) – MTBF (mean time between failures) – MTTR (mean time between repairs) – Idle Time TPM – Operational Goals, cont. (Quantitative) ? Safety – Zero accidents ? Quality – Zero failures – Zero plaints ? Education – Hours of training/ number of sessions – Number of KAIZEN projects – Number of Suggestions TPM – Definition of ?Total? ? Total Effectiveness – Reduction in losses of all equipment to optimize its effectiveness and improve costs ?Total Maintenance – Involves the who