【正文】 Running at reduced speeds ? Constant breakdowns ? After – Crossfunctional Effort ? Replaced broken and missing parts ? Corrected the adjustment ? Returned to designed speed without incurring scrap Control Total Productive Maintenance (TPM) 65 TPM 步驟 2 修復機器的缺漏 ? 目的 :修復在步驟 1中找到的缺漏項目 ? 注意事項 : ? 倡導者 /發(fā)起人需確保標示出的問題得到修復 ? 實際的修復工作不必一定由團隊成員來做 。 ? 生產(chǎn)主管須確保機器能夠使用 Control Total Productive Maintenance (TPM) 66 TPM Step 2 Repair machine defects and leaks ? Purpose: To repair items found in Step 1 ? Considerations: ? Champion/Sponsor insures tagged problems are repaired ? Actual repairs do not have to be done by team members ? Production Supervisor has to make machine available Control Total Productive Maintenance (TPM) 67 TPM 步驟 2 ? 消除故障因素 ? 固定并擰緊所有的扣件 ,接頭 ,螺釘及螺母 ? 替換任何缺損的部件 ? 替換任何損壞 ,磨損及規(guī)格不符的零部件 ? 解決所有的滲漏 ,溢出 ,噴濺 ,噪雜等問題 ? 提高如下環(huán)節(jié)的可操作性 : ? 清潔 ? 潤滑 ? 調試 ? 檢查 /測試 Control Total Productive Maintenance (TPM) 68 TPM Step 2 ? 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 splatter ? Improve accessibility in order to acplish: ? Cleaning ? Lubricating ? Adjusting ? Checking/inspecting Control Total Productive Maintenance (TPM) 69 TPM 步驟 3 建立操作員和維護人員合作的 PM計劃 ? 確保發(fā)出完善的定期檢測的查檢表 目的 : ? 注意事項 : ? 由 TPM項目小組建立 PM計劃 ? 誰來執(zhí)行任務 ? 任務執(zhí)行的頻率 (例如每天 ,每周等 ) Control Total Productive Maintenance (TPM) 70 TPM Step 3 Develop Operator PM’s and Maintenance PM’s ? Purpose: To insure adequate preventative maintenance checklists are posted ? Considerations: ? TPM Project Team to develop PM’s ? Who is to perform tasks ? Frequency of tasks (., daily, weekly, etc.) Control Total Productive Maintenance (TPM) 71 TPM 步驟 4 由操作員執(zhí)行的 PM作業(yè) 目的 :盡早發(fā)現(xiàn)問題 ,準備周期保養(yǎng) ,遵循 5S規(guī)程 ? 注意事項 : ? 操作員負責按照管理文件執(zhí)行 PM工作 。 ? 生產(chǎn)主管須確保 PM工作的有效實施 Control Total Productive Maintenance (TPM) 72 TPM Step 4 PM activity performed by the Operator ? Purpose: To detect early problems, provide the service interval, and insure 5S procedure is followed ? Considerations: ? Operator is responsible to perform PM’s as documented ? Production Supervisor to insure PM’s are effective Control Total Productive Maintenance (TPM) 73 TPM ? TPM使操作員更加獨立地自我管理和控制 。 ? 操作員時時關注小問題的發(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 ? 良好地維持設備整體狀況 Control Total Productive Maintenance (TPM) 74 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 Control Total Productive Maintenance (TPM) 75 自主維護管理 ? 指的是操作員參與自己所操作的設備的維護作業(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 /生產(chǎn)作業(yè)的規(guī)定 ? 明確操作員如何進行日常檢測 ? 進行基本的操作 ,維護及故障檢測的培訓 ? 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 Control Total Productive Maintenance (TPM) 76 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 Control Total Productive Maintenance (TPM) 77 落實自主維護管理 ? 確定過程實施中的關鍵機器及設備 ? 執(zhí)行初步清潔工作 ? 清除臟污及污染源 ? 建立清潔和潤滑標準 ? 就設備的保養(yǎng)需求對操作員進行培訓 ? 貫徹實施一個綜合性的維護系統(tǒng) ? 對保養(yǎng)效果進行定期審查 Control Total Productive Maintenance (TPM) 78 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 Control Total Productive Maintenance (TPM) 79 為什么清潔 ? ? 不恰當?shù)那鍧嵥鶐淼呢撁嬗绊?: ? 故障 ? 產(chǎn)品缺陷 ? 加快設備磨損 ? 產(chǎn)量降低 ? 設備磨損 ? 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)導致加快磨損 Control Total Productive Maintenance (TPM) 80 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 Control Total Productive Maintenance (TPM) 81 清潔可作為磨損檢查 ? 清潔可減緩磨損速度 ? 接觸設備可發(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 Control Total Productive Maintenance (TPM) 82 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 Control Total Productive Maintenance (TPM) 83 常見的設備缺陷 ? 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 ? 防護裝置損壞或不見 Control Total Productive Maintenance (TPM) 84 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 Control Total Productive Maintenance (TPM) 85 設備故障 ? 專家估計與移動裝置相關的機器故障有 60%是由于缺乏或不適當?shù)臐櫥瑢е碌?。 ? 建立設備故障資料庫 ? 收集并管理故障資料 ? 分析故障趨勢及形式 ? 定期展開和發(fā)布總結報告 ? 包括用于定期回顧之用的會議議程報告 Control Total Productive Maintenance (TPM) 86 Equipment Failures ? Experts estimate that 60% of machine breakdowns associated with moving parts are due to lack of or improper lubrication practic