【正文】 ? 生產(chǎn)主管須確保 PM工作的有效實施 71 Total Productive Maintenance (TPM) Control 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 72 Total Productive Maintenance (TPM) Control TPM ? TPM使操作員更加獨立地自我管理和控制 。 6. 規(guī)劃人員配備以確保瓶頸設(shè)備處的滿員運作 35 Total Productive Maintenance (TPM) Control 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 36 Total Productive Maintenance (TPM) Control 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 37 Total Productive Maintenance (TPM) Control 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 38 Total Productive Maintenance (TPM) Control 職責(zé)范圍 ? 精益 6Sigma團隊 ? 倡導(dǎo)者 /發(fā)起人 ? TPM團隊 ? 操作員 ? 現(xiàn)場主管 ? 維護人員 39 Total Productive Maintenance (TPM) Control Areas of Responsibility ? Lean Six Sigma Team ? Champion/Sponsor ? TPM Team ? Operator ? Supervisor ? Maintenance 40 Total Productive Maintenance (TPM) Control 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 41 Total Productive Maintenance (TPM) Control 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 42 Total Productive Maintenance (TPM) Control ? 現(xiàn)場活動 ? 組成 TPM團隊 ? 負責(zé)設(shè)備維護的人員 ? 操作員 ? 一線管理人員 ? 準(zhǔn)備必要的裝備 ? 幫助 TPM團隊診斷異常 ? 協(xié)助跨功能培訓(xùn) ? 收集整理故障標(biāo)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) 43 Total Productive Maintenance (TPM) Control Lean Six Sigma Team Role ? On floor activities ? Assemble the TPM Team ? Maintenance personnel ? Operators ? First line supervision ? Provide necessary equipment ? Help team diagnose abnormalities ? Assist skilled trades ? Collect copies of defect tags and generate a work list ? Provide people resources 44 Total Productive Maintenance (TPM) Control 倡導(dǎo)者 /發(fā)起人的角色 ? 一旦完成現(xiàn)場工作 ,接下來將 : ? 形成工作任務(wù)并跟蹤其完成情況 ? 協(xié)助建立和引入正確的定期維護明細表 ? 協(xié)助維持改善結(jié)果 ? 評估設(shè)備綜合利用率 OEE ? 展示 TPM的改善的成就 45 Total Productive Maintenance (TPM) Control Champion/Sponsor Role ? Upon 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)及機器清潔工作的進行 ? 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 ? 促進生產(chǎn)與維護雙方的合作 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 。till it breaks” 14 Total Productive Maintenance (TPM) Control 主要概念 定期保養(yǎng)是一種基于時間長短或使用狀況對設(shè)備進行檢修的方法 .在指定時間或在使用空檔間對設(shè)備實施檢修作業(yè)以防止設(shè)備發(fā)生故障 . ? 定期保養(yǎng)計劃 預(yù)測性保養(yǎng)是一種基于設(shè)備狀態(tài)的維護方法 .根據(jù)可視信號或檢測技術(shù)的情況來實施保養(yǎng)以防止設(shè)備發(fā)生故障 . ? 振動分析 ? 激光探測 ? 超聲波檢測 ? 發(fā)電機測試 ? 熱感應(yīng) ? 油況分析 預(yù)測性保養(yǎng) 定期保養(yǎng) 15 Total Productive Maintenance (TPM) Control Key Definitions Preventive Maintenance is a time or usage based method of maintaining equipment. Maintenance activities are performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occurring. ? PM Schedules Predictive Maintenance is a situation based method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring. ? Vibration Analysis ? Laser Measuring ? Ultrasound ? Generator Testing ? Thermography ? Oil Analysis Predictive Maintenance Preventive Maintenance 16 Total Productive Maintenance (TPM) Control 現(xiàn)狀分析和團隊組織 ? 評估當(dāng)前的操作條件 : ? 機器利用率 ,生產(chǎn)率等 。 ? 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 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 。 ? 一種源頭監(jiān)控和校正的先發(fā)系統(tǒng) 。 ? 消除導(dǎo)致設(shè)備故障的因素 。 ? 使設(shè)備的養(yǎng)護清潔更易達成 。 ? 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 。 ? 負責(zé)定購和保管所有的工具 ,備件等物資 。 ? 維修費用 (配件和人工 ) ? 對實現(xiàn) TPM的各項工作進行優(yōu)先次序 ? 評估潛在 TPM倡導(dǎo)者及團隊成員的實力 ? 挑選 TPM倡導(dǎo)者及團隊成員 ? 建立初始的實施專門小組 ? 確定團隊目標(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) ?