【文章內(nèi)容簡介】 i ne A op erat i on i s i nt err up t ed by an el ectr i cal probl em f or 31 mi nu t es 2. A n i n proces s qu al i t y che ck t ake s 22 mi nu t es 3. Lo ad un l oa d t i me be t w ee n w i dg et s on machi ne B i s 4 mi nu t es 4. Machi ne X op erat i on i s i nt err up t ed of 8 mi nu t es due t o a mecha ni cal probl em 5. C l ea ni ng t i me on machi ne Z i s 47 mi nu t es 6. Jammed pi ece cau ses machi ne C st op pa ge of 3 mi nu t es 7. Machi ne A pl et es a l oa d at 1: 00 pm an d be gi ns another l oa d ( di f f erent produ ct ) at 2: 27 pm 8 . A sampl e i s t ake n an d t r an spo r t ed t o t he l ab t aki ng 32 mi nu t es 9. 20 0 pi ece s are r e proces sed on machi ne Z 10. Machi ne D r un s at 10 0 pc/hr no t 12 5 pc/hr du e t o l ea ky oi l l i ne s Control Total Productive Maintenance (TPM) 27 OEE的計算原理 承載時間 (LT) 設(shè)備運轉(zhuǎn)總的可利用時間 = 40 hrs 可用水平(AL) 運行水平 (OL) 質(zhì)量水平 (QL) OEE 73% x 91% x 80% = 80% = 91% 質(zhì)量原因 機器故障及輕微故障 , 行政事務(wù) /非作業(yè)時間 機器 設(shè)置與調(diào)整 速度損失 機器空轉(zhuǎn) 返工及 報廢 40 = 73% 40 OEE = 53% AL HRS = 40 = hrs OL HRS = = hrs QL HRS = = hrs Control Total Productive Maintenance (TPM) 28 Calculating OEE Elements Loading Time (LT) Total Hours Available for Equipment Operation = 40 hrs Availability Level (AL) Operating Level (OL) Quality Level (QL) OEE 73% x 91% x 80% = 80% = 91% Quality Factors Breakdowns Minor Stops, and Admin. Setup Speed Losses Idling Rework and Scrap 40 = 73% 40 OEE = 53% AL HRS = 40 = hrs OL HRS = = hrs QL HRS = = hrs Control Total Productive Maintenance (TPM) 29 世界級的 OEE性能水平 承載時間 (LT) 同步計劃運轉(zhuǎn)時間及生產(chǎn)性防護時間 可用水平 (AL) 運行水平 (OL) 質(zhì)量水平 (QL) OEE 90% x 95% x 99% 質(zhì)量 原因 機器故障及 輕微故障 , 行政事務(wù) / 非作業(yè)時間 機器設(shè)置 與調(diào)整 速度 損失 機器 空轉(zhuǎn) 返工及 報廢 OEE = 85% 是世界級的性能水平 AL始終保持在 90%以上 OL維持在 95%以上 QL不低于 99% Control Total Productive Maintenance (TPM) 30 World Class OEE Performance Loading Time (LT) Operation Time and PM Time is scheduled synchronizing the two Availability Level (AL) Operating Level (OL) Quality Level (QL) OEE 90% x 95% x 99% Quality Factors Breakdowns Minor Stops, and Admin. Setup Speed Losses Idling Rework and Scrap OEE = 85% is World Class Performance The AL is consistently kept at or above 90% The OL is maintained at or above 95% The QL is at or above 99% Control Total Productive Maintenance (TPM) 31 使設(shè)備恢復(fù)到可靠狀態(tài) 消除故障 開發(fā) PM維護保養(yǎng)資料庫 消除缺陷 階段 I 階段 II 階段 III 階段 IV TPM 階段 Control Total Productive Maintenance (TPM) 32 Return Equipment to Reliable Condition Eliminate Breakdowns Develop PM Information Database Eliminate Defects PHASE I PHASE II PHASE III PHASE IV TPM Phases Control Total Productive Maintenance (TPM) 33 六大團隊活動 1. 通過小規(guī)模的小組活動來提高機器的正常運行時間 ,消除造成停工的主要根源 : ? 機器的啟動損失 ? 機器的故障損失 ? 待料損失和生產(chǎn)安排不當帶來的停機損失 2. 使操作員熟練地參與如潤滑 ,清潔 , 故障檢驗等基本的保養(yǎng)維護 . Control Total Productive Maintenance (TPM) 34 Six Team Activities 1. Use small group activities to improve machine uptime by eliminating the major sources of downtime. ? Startup Losses ? Breakdown Losses ? Material and Scheduling Losses 2. Involve the machine operators as well as skilled trades in basic preventative maintenance such as lubrication, cleaning, and inspection for defects. Control Total Productive Maintenance (TPM) 35 六大團隊活動 (續(xù)上頁 ) 3. 使用諸如振動分析類的預(yù)測工具擯棄過去那種反應(yīng)式的維護模式 4. 增強對設(shè)備的認知和了解以提高生產(chǎn)效能 ,減少停工時間 。 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) ,避免停機待料 。 6. 規(guī)劃人員配備以確保瓶頸設(shè)備處的滿員運作 Control Total Productive Maintenance (TPM) 36 Six Team Activities (Cont.) 3. Utilize predictive tools such as vibration analysis to move past reactive type maintenance 4. Increase awareness and knowledge of equipment to improve productivity and reduce downtime 5. Work with Supply Management and Production Control to insure a constant flow of raw material is available to preclude idling. 6. Develop manning schedules that insure that bottleneck machines are fully staffed Control Total Productive Maintenance (TPM) 37 TPM的益處 ? 提升操作員的參與感 ? 使設(shè)備恢復(fù)至更高的性能水平 ? 發(fā)現(xiàn)并消除早期的設(shè)備隱患 ? 減少總的制造成本 ? 減少浪費 ? 在保養(yǎng)設(shè)備方面樹立榮譽感 ? 促進維護和生產(chǎn)部門之間的相互尊重與合作 Control Total Productive Maintenance (TPM) 38 Benefits of TPM ? Promotes operator involvement ? Restores equipment to a higher performance level ? Uncover and eliminate premature equipment failures ? Reduce total manufacturing costs ? Reduces waste ? Builds a sense of pride in maintaining the equipment ? Promotes cooperation and respect between maintenance and production Control Total Productive Maintenance (TPM) 39 職責范圍 ? 精益 6Sigma團隊 ? 倡導者 /發(fā)起人 ? TPM團隊 ? 操作員 ? 現(xiàn)場主管 ? 維護人員 Control Total Productive Maintenance (TPM) 40 Areas of Responsibility ? Lean Six Sigma Team ? Champion/Sponsor ? TPM Team ? Operator ? Supervisor ? Maintenance Control Total Productive Maintenance (TPM) 41 精益 6Sigma團隊的任務(wù) ? 確定一個 TPM項目的需求 ? 收集有關(guān)維護成本 ,延遲 (時延或操作延遲 ,設(shè)備利用率以及質(zhì)量問題的歷史數(shù)據(jù) ? 與操作員進行深入溝通以了解他們的期望 Control Total Productive Maintenance (TPM) 42 Lean Six Sigma Team Role ? Determine the need for a TPM Project ? Gather history of maintenance cost, delay, machine availability, and quality problems ? Interview Operators to get their prospective Control Total Productive Maintenance (TPM) 43 ? 現(xiàn)場活動 ? 組成 TPM團隊 ? 負責設(shè)備維護的人員 ? 操作員 ? 一線管理人員 ? 準備必要的裝備 ? 幫助 TPM團隊診斷異常 ? 協(xié)助跨功能培訓 ? 收集整理故障標牌的拷貝并生成工作明細表 ? 提供人力資源方面的支持 精益 6Sigma團隊的任務(wù) Cont