【正文】 m Organization ? Overall Equipment Effectiveness ? TPM Phases RD011202 Control Total Productive Maintenance (TPM) 3 精益 6 ? 過(guò)程改善流程 分析 控制 改進(jìn) 定義 ? 選定題目 ? 列出客戶 ? 從顧客之聲中列出關(guān)建需求 ? 定出項(xiàng)目焦點(diǎn)和重要指標(biāo) ? 完成 PDF 測(cè)量 ? 繪制業(yè)務(wù)流程圖 ? 繪制價(jià)值流程圖 ? 制定數(shù)據(jù)收集計(jì)劃 ? 測(cè)量系統(tǒng)分析 ? 收集數(shù)據(jù) ? 過(guò)程能力分析 分析 ? 提出關(guān)鍵因子 ? 區(qū)分關(guān)鍵因子 ? 驗(yàn)證關(guān)鍵因子 ? 評(píng)枯每個(gè)關(guān)鍵因子對(duì)結(jié)果的影響 ? 量化機(jī)會(huì) ? 根本原因排序 ? 尋找根本原因針對(duì)關(guān)鍵因子 改進(jìn) ? 關(guān)鍵因子確認(rèn) ? 發(fā)掘潛在的解決方法 ? 選擇方案 ? 優(yōu)化方案 ? 實(shí)行方案 控制 ? 過(guò)程變革和控制 ? 制定控制計(jì)劃 ? 計(jì)算最終財(cái)務(wù) ? 過(guò)程指標(biāo) ? 項(xiàng)目過(guò)渡給未來(lái)項(xiàng)目管理者 ? 項(xiàng)目鑒 別 ? 轉(zhuǎn)化機(jī)會(huì) 測(cè)量 定義 ? 項(xiàng)目編號(hào)工具 ? 項(xiàng)目定義表 ? 凈現(xiàn)值分析 ? 內(nèi)部回報(bào)率分析 ? 折算現(xiàn)金流分析 ? PIP管理過(guò)程 ? RACI ? Quad 表 ? 過(guò)程圖 ? 價(jià)值分析 ? 腦力風(fēng)暴 ? 投票歸類法 ? 柏拉圖 ? 因果圖 /魚(yú)骨圖 ? FMEA ? 查檢表 ? 運(yùn)行圖 ? 控制圖 ? 量具 RR ? Cp Cpk ? 供應(yīng)鏈加速器分析 ? 多變動(dòng)圖 i ? 盒狀圖 ? 交互作用圖 ? 回歸分析 ? ANOVA ? CE 矩陣圖 ? FMEA ? 腦力風(fēng)暴 ? 拉系統(tǒng) ? 減少設(shè)置 ? TPM ? 流程圖 ? 標(biāo)桿管理 ? 親和圖 ? DOE ? 假設(shè)檢驗(yàn) ? 力場(chǎng)分析圖 ? 樹(shù)狀圖 ? 甘特圖 ? 查檢表 ? 運(yùn)行圖 ? 柱狀圖 ? 散布圖 ? 控制圖 ? 柏拉圖 ? 互動(dòng)回顧 ? 愚巧法 Revised 11202 Control Total Productive Maintenance (TPM) 4 Lean Six Sigma Improvement Process Road Map Analyze Control Improve Define ? Identify Problem ? Develop List of Customers ?Develop List of CTQ’s from Voice of the Customer ? Finalize Project Focus and Key Metrics ? Complete PDF Measure ? Map Business Process ? Map Value Stream ? Develop Data Collection Plan ? Conduct Measurement System Analysis ? Collect Data ? Conduct Process Capability Analysis Analyze ?Propose Critical X’s ?Prioritize Critical X’s ?Verify Critical X’s ? Estimate the Impact of Each X on Y ? Quantify the Opportunity ? Prioritize Root Causes ? Conduct Root Cause Analysis on Critical X’s Improve ?Critical X’s Confirmed ? Develop Potential Solutions ? Select Solution ? Optimize Solution ? Pilot Solution Control ? Implement Process Changes and Controls ? Write Control Plan ? Calculate Final Financial/ ? Process Metrics ? Transition Project to Future Owners ? Identify Project ? Translation Opportunities Measure Define ? Project ID Tools ? Project Definition Form ? Net Present Value Analysis ? Internal Rate of Return Analysis ? Discounted Cash Flow Analysis ? PIP Management Process ? RACI ? Quad Charts ? Process Mapping ? Value Analysis ? Brainstorming ? MultiVoting Techniques ? Pareto Charts ? CE/Fishbone Diagrams ? FMEA ? Check Sheets ? Run Charts ? Control Charts ? Gage RR ? Cp Cpk ? SupplyChainAccelerator Analysis ? MultiVari ? Box Plots ? Interaction Plots ? Regression ? ANOVA ? CE Matrices ? FMEA ? Brainstorming ? Pull Systems ? Setup Reduction ? TPM ? Process Flow ? Benchmarking ? Affinity ? DOE ? Hypothesis Testing ? Force Field ? Tree Diagrams ? Gantt Charts ? Check Sheets ? Run Charts ? Histograms ? Scatter Diagrams ? Control Charts ? Pareto Charts ? Interactive Reviews ? PokaYoke Revised 11202 Control Total Productive Maintenance (TPM) 5 課程目的 ? 學(xué)習(xí)一種方法以便 : ? 將作業(yè)流程中的起作用的所有生產(chǎn)要素整合為一個(gè)單一綜合的衡量值（ OEE） 。 Control Total Productive Maintenance (TPM) 8 What’s in It for Me? ? Optimized process operations and maintenance ? A method to replace the traditional approach of detecting and correcting faulty conditions as they occur ? A proactive system which monitors and corrects causes ? An operations strategy based on understanding the cause and effect system affecting the major contributors to process performance Control Total Productive Maintenance (TPM) 9 全面生產(chǎn)維護(hù) (TPM) 定義 : ? 一種用于監(jiān)控操作 ,設(shè)備保養(yǎng) ,消除計(jì)劃外停機(jī) ,和提高作業(yè)與保養(yǎng)協(xié)調(diào)程度的常識(shí)性方法。 ? = 實(shí)際運(yùn)行時(shí)間 /可運(yùn)行時(shí)間 ? 效率 : 實(shí)際產(chǎn)量與標(biāo)準(zhǔn)產(chǎn)量的比率 ? = (實(shí)際產(chǎn)量 /小時(shí) )/(標(biāo)準(zhǔn)產(chǎn)量 /小時(shí) ) ? 產(chǎn)出 : 用一特定時(shí)間段的產(chǎn)量來(lái)衡量 ? = 磅 /小時(shí) , 件數(shù) /小時(shí) Control Total Productive Maintenance (TPM) 20 Typical Operational Process Measurements ? Utilization: The ratio of equipment actual operating time to the total available operating time ? = Actual Operating Time/Available Time ? Efficiency: The ratio of actual product produced to a standard ? = (Actual Parts/Hour)/(Standard Part/Hour) ? Output: Measure of output over a specified time period ? = lbs/hr, pieces/hr Control Total Productive Maintenance (TPM) 21 設(shè)備綜合利用率 OEE ? 設(shè)備綜合利用率（ OEE） 是衡量一臺(tái)設(shè)備按計(jì)劃速度生產(chǎn)出合格產(chǎn)品的時(shí)間占全部時(shí)間的百分比 . Control Total Productive Maintenance (TPM) 22 Overall Equipment Effectiveness ? Overall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality product at the designed rate. Control Total Productive Maintenance (TPM) 23 OEE分解 :六大浪費(fèi) 故障及輕微故障 使設(shè)備中斷運(yùn)行的時(shí)間超過(guò) 10分鐘的故障或者中斷時(shí)間少于 10分鐘的輕微故障 . 設(shè)置時(shí)間浪費(fèi) 任何與設(shè)備調(diào)整 ,裝配 ,清潔相關(guān)的作業(yè) . 機(jī)器空轉(zhuǎn)浪費(fèi) 設(shè)備在運(yùn)轉(zhuǎn)卻沒(méi)有用來(lái)生產(chǎn)產(chǎn)品所耗用的時(shí)間 . 速度浪費(fèi) 由于設(shè)備或產(chǎn)品的異常造成設(shè)備以低于標(biāo)準(zhǔn)速度或所設(shè)定的速度運(yùn)轉(zhuǎn) . 品質(zhì)原因浪費(fèi) 為確保設(shè)備產(chǎn)出品的品質(zhì)而采取相關(guān)的作業(yè) (過(guò)程中檢查 ). 返工浪費(fèi) 用于返修產(chǎn)品或生產(chǎn)出報(bào)廢產(chǎn)品所耗用的時(shí)間 . 可用水平 (AL) 運(yùn)行水平 (OL) 質(zhì)量水平 (QL) Control Total Productive Maintenance (TPM) 24 OEE Breakdown: The Six Big Losses Breakdowns and Minor Stoppages Malfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages) Setup Any activity related to equipment changeover, setup, or cleaning. Idling Time equipment is running but not producing product. Speed Losses Equipment operating at less than standard or design speed due to equipment/product abnormality Quality Factors Activities related to ensuring the quality of the product produced on the equipment (inprocess checks). Rework Losses The time taken to reprocess product or time take to produce unusable product. Availability Level (AL) Operating Level (OL) Quality Level (QL) Control Total Productive Maintenance (TPM) 25 六大浪費(fèi)