【正文】 ctive 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(tuán)隊(duì)組織 ? 評(píng)估當(dāng)前的操作條件 : ? 機(jī)器利用率 ,生產(chǎn)率等 。 ? = 實(shí)際運(yùn)行時(shí)間 /可運(yùn)行時(shí)間 ? 效率 : 實(shí)際產(chǎn)量與標(biāo)準(zhǔn)產(chǎn)量的比率 ? = (實(shí)際產(chǎn)量 /小時(shí) )/(標(biāo)準(zhǔn)產(chǎn)量 /小時(shí) ) ? 產(chǎn)出 : 用一特定時(shí)間段的產(chǎn)量來衡量 ? = 磅 /小時(shí) , 件數(shù) /小時(shí) 19 Total Productive Maintenance (TPM) Control Typical Operational Process Measurements ? Utilization: The ratio of equipment actual operating time to the total available operating time ? = Actual Operating Time/Available Time ? Efficiency: The ratio of actual product produced to a standard ? = (Actual Parts/Hour)/(Standard Part/Hour) ? Output: Measure of output over a specified time period ? = lbs/hr, pieces/hr 20 Total Productive Maintenance (TPM) Control 設(shè)備綜合利用率 OEE ? 設(shè)備綜合利用率（ OEE） 是衡量一臺(tái)設(shè)備按計(jì)劃速度生產(chǎn)出合格產(chǎn)品的時(shí)間占全部時(shí)間的百分比 . 21 Total Productive Maintenance (TPM) Control Overall Equipment Effectiveness ? Overall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality product at the designed rate. 22 Total Productive Maintenance (TPM) Control OEE分解 :六大浪費(fèi) 故障及輕微故障 使設(shè)備中斷運(yùn)行的時(shí)間超過 10分鐘的故障或者中斷時(shí)間少于 10分鐘的輕微故障 . 設(shè)置時(shí)間浪費(fèi) 任何與設(shè)備調(diào)整 ,裝配 ,清潔相關(guān)的作業(yè) . 機(jī)器空轉(zhuǎn)浪費(fèi) 設(shè)備在運(yùn)轉(zhuǎn)卻沒有用來生產(chǎn)產(chǎn)品所耗用的時(shí)間 . 速度浪費(fèi) 由于設(shè)備或產(chǎn)品的異常造成設(shè)備以低于標(biāo)準(zhǔn)速度或所設(shè)定的速度運(yùn)轉(zhuǎn) . 品質(zhì)原因浪費(fèi) 為確保設(shè)備產(chǎn)出品的品質(zhì)而采取相關(guān)的作業(yè) (過程中檢查 ). 返工浪費(fèi) 用于返修產(chǎn)品或生產(chǎn)出報(bào)廢產(chǎn)品所耗用的時(shí)間 . 可用水平 (AL) 運(yùn)行水平 (OL) 質(zhì)量水平 (QL) 23 Total Productive Maintenance (TPM) Control OEE Breakdown: The Six Big Losses Breakdowns and Minor Stoppages Malfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages) Setup Any activity related to equipment changeover, setup, or cleaning. Idling Time equipment is running but not producing product. Speed Losses Equipment operating at less than standard or design speed due to equipment/product abnormality Quality Factors Activities related to ensuring the quality of the product produced on the equipment (inprocess checks). Rework Losses The time taken to reprocess product or time take to produce unusable product. Availability Level (AL) Operating Level (OL) Quality Level (QL) 24 Total Productive Maintenance (TPM) Control 六大浪費(fèi)的識(shí)別練習(xí) 識(shí)別損失類別12345678910機(jī)器A 在下午1 點(diǎn)鐘完成一產(chǎn)品裝配而在下午2 : 2 7 開始另一產(chǎn)品的裝配工作現(xiàn)象由于電氣故障機(jī)器A 的運(yùn)轉(zhuǎn)中斷3 1 分鐘過程中的質(zhì)量檢查耗時(shí)2 2 分鐘機(jī)器B 上的小裝置裝卸時(shí)間為4 分鐘由于機(jī)械故障機(jī)器X 運(yùn)轉(zhuǎn)中斷8 分鐘機(jī)器Z 的清潔時(shí)間為4 7 分鐘工件被軋住造成機(jī)器C 中斷3 分鐘從取樣到送至實(shí)驗(yàn)室耗時(shí)3 2 分鐘機(jī)器Z 返修2 0 0 個(gè)工件由于機(jī)油線路泄漏機(jī)器D 僅能以每小時(shí)加工1 0 0 片產(chǎn)品的速度運(yùn)行達(dá)不到1 2 5 片的標(biāo)準(zhǔn) S C E N A R I O L O S S I D E N T I F I C A T I O N 1. M a c h i n e A o p e r a t i o n i s i n t e r r u p t e d b y a n e l e c t r i c a l p r o b l e m f o r 3 1 m i n u t e s 由于電氣故障機(jī)器 A 的運(yùn)轉(zhuǎn)中斷 31 分鐘 2. A n i n p r o c e s s q u a l i t y c h e c k t a k e s 2 2 m i n u t e s 3. L o a d u n l o a d t i m e b e t w e e n w i d g e t s o n m a c h i n e B i s 4 m i n u t e s 機(jī)器 B 上的小部件 裝卸的時(shí) 間 為 4 分鐘 4. M a c h i n e X o p e r a t i o n i s i n t e r r u p t e d o f 8 m i n u t e s d u e t o a m e c h a n i c a l p r o b l e m 由于機(jī)械故障機(jī)器 X 運(yùn)轉(zhuǎn)中斷 8 分鐘 5. C l e a n i n g t i m e o n m a c h i n e Z i s 4 7 m i n u t e s 機(jī)器 Z 的清潔時(shí)間為47 分鐘 6. J a m m e d p i e c e c a u s e s m a c h i n e C s t o p p a g e o f 3 m i n u t e s 7. M a c h i n e A c o m p l e t e s a l o a d a t 1 : 0 0 p m a n d b e g i n s a n o t h e r l o a d ( d i f f e r e n t p r o d u c t ) a t 2 : 2 7 p m 8. A s a m p l e i s t a k e n a n d t r a n s p o r t e d t o t h e l a b t a k i n g 3 2 m i n u t e s 9. 2 0 0 p i e c e s a r e r e p r o c e s s e d o n m a c h i n e Z 10. M a c h i n e D r u n s a t 1 0 0 p c / h r n o t 1 2 5 p c / h r d u e t o l e a k y o i l l i n e s 25 Total Productive Maintenance (TPM) Control Six Big Losses Identification Exercise S C E N A R I O L O S S I D E N T I F I C A T I O N 1. Machi 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 26 Total Productive Maintenance (TPM) Control OEE的計(jì)算原理 承載時(shí)間 (LT) 設(shè)備運(yùn)轉(zhuǎn)總的可利用時(shí)間 = 40 hrs 可用水平(AL) 運(yùn)行水平 (OL) 質(zhì)量水平 (QL) OEE 73% x 91% x 80% = 80% = 91% 質(zhì)量原因 機(jī)器故障及輕微故障 , 行政事務(wù) /非作業(yè)時(shí)間 機(jī)器 設(shè)置與調(diào)整 速