【文章內(nèi)容簡介】 ailures Loose parts Vibration Contamination Improper/ Inadequate Lubrication 33 Eliminate Factors Contributing to Failure: ? Secure and tighten all fasteners, fittings, bolts and screws ? Replace any missing parts ? Replace any damaged, worn or wrong size parts ? Resolve all causes of leaks, spillage, spray and scatter Improve accessibility in order to acplish ? Cleaning ? Lubricating ? Adjusting ? Checking 34 Total Productive Maintenance Self Maintenance Operator ________________________ Equipment Description .________Date:_______ Found by:________________ Description: Description: Total Productive Maintenance Self Maintenance Maintenance ________________________ Equipment Description .________Date:_______ Found by:________________ Autonomous Maintenance: Tagging Abnormalities 35 Tagging Abnormalities Cleaning will uncover problems and undesirable conditions. ?Attach tag to make problem visible ?Resolves problems promptly and remove tags. ?Document plans to address those that can’t be removed immediately. Autonomous Maintenance 36 Before Tags are Removed, Ask The 5 “Whys” Problem: Oil leaks from the hydraulic press 1. Why? Clogged filter 2. Why? Oil was dirty 3. Why? Metal filings got into oil 4. Why? Oil fill cap missing 5. Why? Misplaced lost Find the root cause Solution! Oil filler cap attached to filler neck by a chain (PokaYoke) 37 Equipment Performance Losses ? Downtime losses time lost to equipment breakdowns, machine adjustments ? Efficiency losses time lost to start up and operating cycle speeds less than ideal ? Defect losses time lost to machine related quality defects and recycling. 38 Equipment Performance Losses Loss Goal Ac tionDo w n timeL ossesZero El i m inat e br eak d owns a n dint erm i tt ent st op p ages .E ff ic ie ncyL ossesM inim iz e Shr i nk set up an d a d j u st m ent t i m es.M inim iz e differ e nces betwee n rat edand ac tual e qu ipm ent s peeds .Defec ts Rew orkL ossesZero R edu ce to a m inim u m PPM rang e of3010 0.39 Assignable Loss versus Common Loss Defect rate Time Assignable loss corrected by restoring to original conditions Common loss reduced by achieving optimal conditions 40 Importance of Lubrication ? Some experts estimate 60% of machine breakdowns associated with moving parts are due to lack of or improper lubrication practices. M ov i n g P ar t M ac h i n e Br e ak d ow n s60%40%L u b r i c a t i o n r e l a t e dO t h e r c a u s e s41 Lubrication Management ? The need to lubricate equipment correctly and consistently ? according to usage ? with correct lubricants ? in the correct amount ? at specified fittings ? at specified time intervals ? ensuring coverage of contact areas 42 Visual Management of Lubricants Green Blue Orange Red w/ White stripe Oil Grease Hydraulic fluid Silicone 43 Maintenance Checklists TPM VERIFICATION LIST At The Beginning of Each Shift ?Hydraulic Pressure ?Leaks (oil, fluids) ?Caps and hoses ?Switches ?Lights and lamps ?Body ?Noises/vibration At The End of Each Shift ?Clean ?Make entry in maintenance book 44 1 2 3 4 5 6 7 8 9 10 Example Cleaning and Lubrication for Autonomous Maintenance 45 Basic Training in Equipment ? Conduct equipment training for leaders. ? Leaders then train group members. ? Operators implement training to correct abnormalities and improve equipment performance. ? Implement visual controls. 46 Example Skills Matrix Basic Training in Equipment Operation 10 20 30 40 50 60 Equipment type SMD Chipshooter Cut Clinch Pin Bushing Wave solder PostWave Wash David B. Linda W. Matt S. Debbie M. Steve H. John S. Jessica L. Legend: Knows basics