【正文】 engineering and maintenance for improving overall performance of machines 將生產(chǎn)部變成 PE和 ME的積極伙伴來改善機器的總效能 Belton Confidential ?? How to achieve Autonomous Maintenance 如何達到自主維護 ? 5S Management 5S管理 ? Visual Management 目視管理 ? Standardized Work 標(biāo)準(zhǔn)化作業(yè) ? Equipment operation skill enhancement 提高 設(shè)備 操作技術(shù) ? Break down barriers 打破障礙 ? High level maintenance management 高水平維護管理 Ownership responsibility 主人翁精神 Transfer of PM activities to operator 員工參與技術(shù)性的維護活動 All employees involved 全員參與 Belton Confidential ?? Autonomous Maintenance for assembly line 裝配生產(chǎn)線自主維護 裝配生產(chǎn)線的自主維護6 大點步驟 活動要點 步驟 活動要點第1點 初期清掃清理一切不必要的徹底清除垃圾,污染,灰塵有用零件,工具,產(chǎn)品的標(biāo)示第4點 總點檢工具,器具,儀表總點檢計劃檢查防錯系統(tǒng)的開發(fā)第2點 操作整頓避免作風(fēng)散布對策部件拿取容易的對策蹲,彎腰動作的對策零件 FI FO (先進先出)改善第5點 JIT 意識零件供給 , 物料進出反饋零件工作臺的高度和方向最佳化WI P 控制 , 最適合庫存品質(zhì)反饋系統(tǒng)產(chǎn)品搬運,人員走動的適當(dāng)化第3點 制訂基準(zhǔn)清掃點檢標(biāo)準(zhǔn)的擬定作業(yè)標(biāo)準(zhǔn)的擬定人員配比員工多技能培訓(xùn)表第6點 標(biāo)準(zhǔn)化作業(yè)工序穩(wěn)定作業(yè)標(biāo)準(zhǔn)與總點檢標(biāo)準(zhǔn)整合防止品質(zhì)不良構(gòu)筑柔性生產(chǎn)構(gòu)筑標(biāo)準(zhǔn)生產(chǎn)系統(tǒng)Belton Confidential ?? ? The key focus of a Lean factory is to establish a process system which is Fast, Flexible Predictable 精益工廠的核心目的是建立一個快速的 ﹑ 靈活的和可預(yù)見的系統(tǒng) ? All equipment sets don?t perform at a same fixed rates all the time. Equipment sets perform with variable standards of performance 所有的設(shè)備不會一直以同樣的速度工作 ﹐ 它們有自己的變異 ? Each piece of equipment in a progressively arranged line is dependant on the event of other equipment in the line. This is called statistical fluctuation of dependent events 每臺設(shè)備的產(chǎn)能依存于這條生產(chǎn)線其它設(shè)備的運行狀況 ﹐ 這叫做獨立事件的統(tǒng)計波動 Statistical fluctuation 統(tǒng)計波動 Belton Confidential ?? When each piece of equipment is not producing at a predictable tact time the effects are 當(dāng)每臺設(shè)備不以妳期望的節(jié)拍生產(chǎn)時會導(dǎo)致 : High inventory holding at random locations to cushion downtime 庫存會隨機的堆積在工序中來應(yīng)付停機 Non linear flow of parts 產(chǎn)品不會直線性的連續(xù)流動 Bottlenecks starve for parts or are not optimised 瓶頸工序挨餓或者優(yōu)化不夠 Therefore you need to reduce the variability by improving equipment performance to improve the productivity(UPMH)rather than adding WIP or investing on capital 所以提高生產(chǎn)力 , 你必須降低設(shè)備的變異 , 而不是增加 WIP或者購買設(shè)備 ﹒ Statistical fluctuation 統(tǒng)計波動 Belton Confidential ?? Equipment Losses Understanding 理解設(shè)備損失 Belton Confidential ?? The seven big losses 七大損耗 Down Time: 停機 ?Equipment failure(breakdowns)設(shè)備故障 ?Preventive Maintenance 預(yù)防維護 ?Setup and adjustment 切換和調(diào)整 Speed Losses: 速度損失 ?Idling and minor stoppages 點點停 ?Reduced speed 速度低下 Defect: 不良 ?Process defects due to scrap and quality 過程不良 運行中產(chǎn)生的不良品 ?Reduced yield machine startup 開機品質(zhì)低下 啟動產(chǎn)生的不良品 M a j orBre a kdow nM i norBre a kdow nS e t up T i m eQ ua l i fi c a t i onT i m eM a j or P MM i nor P MO t he rIdl e N o W IPIdl e N oO p e ra t orIdl e Cons um a bl e sIne ffe c t i veP roc e s s i ngT i m e S p e e dIne ffe c t i veP roc e s s i ngT i m e Q ua l i t yE ffe c t i veP roc e s s i ngT i m eL oa d /U nl oa dBelton Confidential ?? TPM Equipment Improvement TPM 設(shè)備改善 The tools which are used to improve equipment lossess include 用來改善設(shè)備損耗的工具有 : ?Set Up Time Reduction 快速切換 ?Error Proofing 防錯法 ?5S and Task Transfer 5S和責(zé)任轉(zhuǎn)移 ?KANBAN Drum Buffer Rope 看板 ﹐ 鼓 － 緩沖器 － 繩子 ?Equipment FMEA Six Sigma ?Visual Control System 目視管理 ?Standardised Work 標(biāo)準(zhǔn)化作業(yè) Belton Confidential ?? TPMApproach 步驟 Analysis Correction Prevention 分析 預(yù)防 改良 Belton Confidential ?? Analysis 分析 Solving maintenance problems requires indepth understanding of equipment performance 解決維修問題需要對設(shè)備的性能有深刻的理解 Necessary to truly understand cause effect 需要真正理解因果關(guān)系 ?What information do you currently have to understand equipment issues 目前你有哪些信息來了解設(shè)備問題 ? ?Maintenance records 維修記