【正文】 ? 操作員時時關(guān)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(shè)備整體狀況 73 Total Productive Maintenance (TPM) Control 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 74 Total Productive Maintenance (TPM) Control 自主維護(hù)管理 ? 指的是操作員參與自己所操作的設(shè)備的維護(hù)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(hù) /生產(chǎn)作業(yè)的規(guī)定 ? 明確操作員如何進(jìn)行日常檢測 ? 進(jìn)行基本的操作 ,維護(hù)及故障檢測的培訓(xùn) ? 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 75 Total Productive Maintenance (TPM) Control 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 76 Total Productive Maintenance (TPM) Control 落實自主維護(hù)管理 ? 確定過程實施中的關(guān)鍵機(jī)器及設(shè)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(biāo)準(zhǔn) ? 就設(shè)備的保養(yǎng)需求對操作員進(jìn)行培訓(xùn) ? 貫徹實施一個綜合性的維護(hù)系統(tǒng) ? 對保養(yǎng)效果進(jìn)行定期審查 77 Total Productive Maintenance (TPM) Control 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 78 Total Productive Maintenance (TPM) Control 為什么清潔 ? ? 不恰當(dāng)?shù)那鍧嵥鶐淼呢?fù)面影響 : ? 故障 ? 產(chǎn)品缺陷 ? 加快設(shè)備磨損 ? 產(chǎn)量降低 ? 設(shè)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(dǎo)致加快磨損 79 Total Productive Maintenance (TPM) Control 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 80 Total Productive Maintenance (TPM) Control 清潔可作為磨損檢查 ? 清潔可減緩磨損速度 ? 接觸設(shè)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 81 Total Productive Maintenance (TPM) Control 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 82 Total Productive Maintenance (TPM) Control 常見的設(shè)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(hù)裝置損壞或不見 83 Total Productive Maintenance (TPM) Control 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 84 Total Productive Maintenance (TPM) Control 設(shè)備故障 ? 專家估計與移動裝置相關(guān)的機(jī)器故障有 60%是由于缺乏或不適當(dāng)?shù)臐櫥瑢?dǎo)致的 。 ? 生產(chǎn)主管須確保機(jī)器能夠使用 65 Total Productive Maintenance (TPM) Control 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 66 Total Productive Maintenance (TPM) Control 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(diào)試 ? 檢查 /測試 67 Total Productive Maintenance (TPM) Control 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 68 Total Productive Maintenance (TPM) Control TPM 步驟 3 建立操作員和維護(hù)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(wù) ? 任務(wù)執(zhí)行的頻率 (例如每天 ,每周等 ) 69 Total Productive Maintenance (TPM) Control 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.) 70 Total Productive Maintenance (TPM) Control 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(zhǔn)備周期保養(yǎng) ,遵循 5S規(guī)程 ? 注意事項 : ? 操作員負(fù)責(zé)按照管理文件執(zhí)行 PM工作 。 ? 使用振動分析 ,磨損度分析 ,熱感應(yīng)等預(yù)測工具 。 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(jī)待料 。 ? 維修費(fèi)用 (配件和人工 ) ? 對實現(xiàn) TPM的各項工作進(jìn)行優(yōu)先次序 ? 評估潛在 TPM倡導(dǎo)者及團(tuán)隊成員的實力 ? 挑選 TPM倡導(dǎo)者及團(tuán)隊成員 ? 建立初始的實施專門小組 ? 確定團(tuán)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) ? Prioritize order of TPM efforts ? Assess capabilities of potential TPM Champions and Team Members ? Select TPM Champion and Team Members ? Establish initial kickoff workshop ? Establish team goal 18 Total Productive Maintenance (TPM) Control 典型的設(shè)備評價指標(biāo) ? 利用率 : 設(shè)備實際運(yùn)轉(zhuǎn)時間與總的可利用時間的比率 。 ? 一直用到壞了為止 13 Total Productive Maintenance (TPM) Control Traditional Approach “ReActive Maintenance” Maintenance – “WE FIX” ? Perform all maintenance activities ? Perform “Fire Fighting” maintenance when a machine breakdown occurs ? Order and administer all tooling, supplies, etc. ? Perform Preventive Maintenance Manufacturing – “WE OPERATE” ? Generally does not perform any maintenan