【正文】 n Completion of On Floor Event ? Generate and track pletion of work orders ? Assist in creation and posting of accurate Periodic Maintenance List ? Assist in sustaining the gains ? Evaluate Overall Equipment Effectiveness ? Display TPM improvements 46 Total Productive Maintenance (TPM) Control 現(xiàn)場主管的角色 ? 指導(dǎo)并推廣 TPM概念 ? 監(jiān)控現(xiàn)場的設(shè)備管理 ,保養(yǎng)及機(jī)器清潔工作的進(jìn)行 ? 激發(fā)操作員的主人翁意識 ? 對操作員授權(quán) ? 為 TPM活動提供時間方面的準(zhǔn)備 ? 促進(jìn)生產(chǎn)與維護(hù)雙方的合作 47 Total Productive Maintenance (TPM) Control Supervisor’s Role ? Coach and promote TPM Concepts ? Monitor ongoing housekeeping and machine cleanliness ? Promote Operator ownership ? Empower Operators ? Provide time for TPM activities ? Promote cooperation between Production and Maintenance 48 Total Productive Maintenance (TPM) Control 維護(hù)人員的角色 “專業(yè)的管理者” ? 有計劃的實施所有的定期保養(yǎng)并根據(jù)需要采取維修措施 。 ? 預(yù)防工作將立足于以下方面 : ? 維持正常的生產(chǎn)條件 ? 及早發(fā)現(xiàn)異常 ? 快速反應(yīng) 11 Total Productive Maintenance (TPM) Control TPM ? Achieve zero equipment breakdowns and zero defects through prevention ? Establish prevention by ? Maintaining normal conditions ? Early detection of abnormalities ? Quick response 12 Total Productive Maintenance (TPM) Control 傳統(tǒng)的反應(yīng)式維護(hù) 維修部門 – “我們只管修理” ? 執(zhí)行所有的維修作業(yè) ? 往往是一旦設(shè)備發(fā)生故障充當(dāng)救火員的角色 。 ? 消除導(dǎo)致設(shè)備故障的因素 。 ? 一種基于對影響過程性能的主要因素其因果系統(tǒng)的理解工作策略 。 ? 維修費(fèi)用 (配件和人工 ) ? 對實現(xiàn) TPM的各項工作進(jìn)行優(yōu)先次序 ? 評估潛在 TPM倡導(dǎo)者及團(tuán)隊成員的實力 ? 挑選 TPM倡導(dǎo)者及團(tuán)隊成員 ? 建立初始的實施專門小組 ? 確定團(tuán)隊目標(biāo) 17 Total Productive Maintenance (TPM) Control 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 18 Total Productive Maintenance (TPM) Control 典型的設(shè)備評價指標(biāo) ? 利用率 : 設(shè)備實際運(yùn)轉(zhuǎn)時間與總的可利用時間的比率 。 ? 操作員時時關(guān)注小問題的發(fā)生就有可能 : ? 迅速地發(fā)現(xiàn)潛在的問題 ? 修正現(xiàn)有問題 ? 確定狀態(tài)正常 ? 良好地維持設(shè)備整體狀況 73 Total Productive Maintenance (TPM) Control TPM ? TPM makes the operator more independent ? The operator sees the small problems now with the possibility of: ? Quickly noting potential problems ? Correcting the current situation ? Recognizing normal conditions ? Maintaining the machine in good overall condition 74 Total Productive Maintenance (TPM) Control 自主維護(hù)管理 ? 指的是操作員參與自己所操作的設(shè)備的維護(hù)作業(yè) ? 怎樣使操作員更加自主 ,實現(xiàn)自我管理 : ? 利用文件管理 ? 明確維護(hù) /生產(chǎn)作業(yè)的規(guī)定 ? 明確操作員如何進(jìn)行日常檢測 ? 進(jìn)行基本的操作 ,維護(hù)及故障檢測的培訓(xùn) ? 使日常作業(yè)直觀 ,一目了然 ? 明確識別須監(jiān)督管理的項目 75 Total Productive Maintenance (TPM) Control Autonomous Maintenance ? Refers to activities involving operators in the maintenance of their own equipment ? How to make the operator more independent: ? Make documentation available ? Define maintenance/manufacturing activities ? Show operator how to perform daily checks ? Train in basic operation, maintenance, and defect detection ? Make daily activities visible ? Clearly identify items to supervise 76 Total Productive Maintenance (TPM) Control 落實自主維護(hù)管理 ? 確定過程實施中的關(guān)鍵機(jī)器及設(shè)備 ? 執(zhí)行初步清潔工作 ? 清除臟污及污染源 ? 建立清潔和潤滑標(biāo)準(zhǔn) ? 就設(shè)備的保養(yǎng)需求對操作員進(jìn)行培訓(xùn) ? 貫徹實施一個綜合性的維護(hù)系統(tǒng) ? 對保養(yǎng)效果進(jìn)行定期審查 77 Total Productive Maintenance (TPM) Control Autonomous Maintenance Implementation ? Identify process critical machinery and equipment ? Perform initial cleaning ? Resolve sources of dirt and contamination ? Create cleaning and lubrication standards ? Train operators on equipment maintenance requirements ? Implement a prehensive maintenance system ? Establish periodic audits of maintenance effectiveness 78 Total Productive Maintenance (TPM) Control 為什么清潔 ? ? 不恰當(dāng)?shù)那鍧嵥鶐淼呢?fù)面影響 : ? 故障 ? 產(chǎn)品缺陷 ? 加快設(shè)備磨損 ? 產(chǎn)量降低 ? 設(shè)備磨損 ? 正常磨損 : 盡管正確操作仍然會發(fā)生 ? 加快磨損 : 由于誤操作及疏忽于保養(yǎng)導(dǎo)致加快磨損 79 Total Productive Maintenance (TPM) Control Why Clean? ? Adverse effects of inadequate cleaning ? Failure ? Product defects ? Accelerated deterioration ? Throughput loss ? Equipment deterioration ? Normal deterioration: occurs despite correct use ? Accelerated deterioration: quicker deterioration occurring due to misuse in operation and neglect of maintenance 80 Total Productive Maintenance (TPM) Control 清潔可作為磨損檢查 ? 清潔可減緩磨損速度 ? 接觸設(shè)備可發(fā)現(xiàn)異常情況 ? 采取保養(yǎng)措施可延長使用壽命 ,避除故障 81 Total Productive Maintenance (TPM) Control Cleaning as Detection of Deterioration ? Cleaning reduces accelerated deterioration ? Physical contact with equipment exposes abnormal operation conditions ? Preventive action taken extends useful life and avoids breakdowns 82 Total Productive Maintenance (TPM) Control 常見的設(shè)備缺陷 ? 斷線 ? 軟管磨破 ? 漏油 ? 漏氣 ? 散熱劑泄漏 ? 托架損壞 ? 電線裸露 ? 多余及廢棄的器具 ? 防護(hù)裝置損壞或不見 83 Total Productive Maintenance (TPM) Control Typical Defects Found ? Broken flex ? Worn hoses ? Oil leaks ? Air Leaks ? Coolant leaks ? Broken Brackets ? Frayed wires ? Unnecessary and obsolete tooling ? Damaged or missing guards 84 Total Productive Maintenance (TPM) Control 設(shè)備故障 ? 專家估計與移動裝置相關(guān)的機(jī)器故障有 60%是由于缺乏或不適當(dāng)?shù)臐櫥瑢?dǎo)致的 。 5. 使供應(yīng)管理和生產(chǎn)調(diào)度協(xié)同工作以確保持續(xù)穩(wěn)定的原材料供應(yīng) ,避免停機(jī)待料 。 9 Total Productive Maintenance (TPM) Control Total Productive Maintenance (TPM) TPM Definition ? A mon sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance. 10 Total Productive Maintenance (TPM) Control TPM ? 通過實施預(yù)防實現(xiàn)設(shè)備零故障和零缺陷 。Measure Analyze Control Improve Lean Six Sigma 全面生產(chǎn)維護(hù) (TPM) ? TPM ? TPM 團(tuán)隊組織 ? 設(shè)備綜合利用率 OEE ? TPM 活動步驟 RD011202 Measure Analyze Control Improve Lean Six Sigma Total Productive Maintenance (TPM) ? TPM ? TPM Team Organization ? Overall Equipment Effectiveness ? TPM Phases RD011202 Control 精益 6 ? 過程改善流程 分析 控制 改進(jìn) 定義 ? 選定題目 ? 列出客戶 ? 從顧客之聲中