【正文】 Breakdowns ?Cost 成本 More Effective Use of Manpower Reduced Maintenance Costs Reduced Energy Costs ?Quality 品質 Reduced Defects in Process Reduced Customer Claims ?Morale 士氣 Increase in Improvement Ideas Improved Communication through small group meetings ?Delivery 交付 Increased Schedule Adherence Increased Stock Turns ?Safety /Environment安全 /環(huán)境 Zero Accidents Zero Pollution Belton Confidential ?? Overview of Autonomous Maintenance 自主維護概述 Objectives 目的 ? Improve machine and work productivity 提高產(chǎn)能 ? Improve employee morale 提供雇員士氣 ? Improve work satisfaction 提高工作滿意度 ? Reduce unplanned downtime 降低非計劃停機時間 ? Reduce speed loss 降低速度損耗 Belton Confidential ?? Operational Roles 運作角色 In TPM maintenance is asking for manufacuturing assistance. 在 TPM中維修請求生產(chǎn)幫助 In TPM manufacturing is asking for maintenance assistance. 在 TPM中生產(chǎn)請求維修幫助 Both departments are the wheels of the same car. 兩個部門相當于同一輛車上的輪子 Operator 操作員 Maintenance 維修員 Belton Confidential ?? Change Attitude 態(tài)度改變 Dramatic change in attitude 在態(tài)度上的戲劇性變化 Old attitude 老的態(tài)度 ? it is no the operator?s responsibility to perform cleaning and inspection 清潔和檢查不是員工的責任 ? all equipment will eventually give faults and failure 所有設備終究會有毛病和故障 ? all faults and failures of equipment can be rectified by maintenance 所有毛病和故障都須維修員來處理 New attitude 新的態(tài)度 ? We share responsibility for caring of our machine, as if they are extensions of our limbs and arms 我們要分擔責任來看護機器 ﹐ 把機器當作我們的四肢 I t 39。s y ou r pr obl e m ! !A ll e qu ipm e n t h a v e f a u lt sa n d f a ilu r e sBelton Confidential ?? Benefits of Atuonomous Maintenance 自主維護的好處 ? Benefits of Autonomous Maintenance include 自主維護的好處 ?Improve Productivity 提高生產(chǎn)力 ?Improve Quality 改善品質 ?Reduced Cycle Time 降低周期時間 ?Reduce Speed Loss 降低速度損耗 ?Reduce Equipment Maintenance Cost 降低設備維修成本 ?Improve team work and cross functional relationship 加強團隊合作和相互關系 ? Value of Autonomous Maintenance 自主維護的價值 ?Change of work culture from “I can only operate this machine” to “machine is a part of my duty” 改變工作文化 ,從“我是這臺設備的操作員 ” 到“設備是我職責的一部分” ?Equipment problems are opportunities for improvement 設備的問題也就是改善的機會 Belton Confidential ?? Training 培訓 ? To develop a knowledgeable operator 培養(yǎng)有見識的員工 ? How equipment functions? 設備怎么運作 ? ?What mon problem occurs? 什么樣的常見問題發(fā)生 ? ?How to detect problems through five senses/feeling? 怎樣通過五官 /感覺來發(fā)現(xiàn)問題 ? ?That there is something ?FUNNY?? 有趣嗎 ? ?why and how those simple problems can be prevented? 這些簡單的問題怎樣預防 ? ? To make manufacturing an active partner with process engineering and maintenance for improving overall performance of machines 將生產(chǎn)部變成 PE和 ME的積極伙伴來改善機器的總效能 Belton Confidential ?? How to achieve Autonomous Maintenance 如何達到自主維護 ? 5S Management 5S管理 ? Visual Management 目視管理 ? Standardized Work 標準化作業(yè) ? Equipment operation skill enhancement 提高 設備 操作技術 ? Break down barriers 打破障礙 ? High level maintenance management 高水平維護管理 Ownership responsibility 主人翁精神 Transfer of PM activities to operator 員工參與技術性的維護活動 All employees involved 全員參與 Belton Confidential ?? Autonomous Maintenance for assembly line 裝配生產(chǎn)線自主維護 裝配生產(chǎn)線的自主維護6 大點步驟 活動要點 步驟 活動要點第1點 初期清掃清理一切不必要的徹底清除垃圾,污染,灰塵有用零件,工具,產(chǎn)品的標示第4點 總點檢工具,器具,儀表總點檢計劃檢查防錯系統(tǒng)的開發(fā)第2點 操作整頓避免作風散布對策部件拿取容易的對策蹲,彎腰動作的對策零件 FI FO (先進先出)改善第5點 JIT 意識零件供給 , 物料進出反饋零件工作臺的高度和方向最佳化WI P 控制 , 最適合庫存品質反饋系統(tǒng)產(chǎn)品搬運,人員走動的適當化第3點 制訂基準清掃點檢標準的擬定作業(yè)標準的擬定人員配比員工多技能培訓表第6點 標準化作業(yè)工序穩(wěn)定作業(yè)標準與總點檢標準整合防止品質不良構筑柔性生產(chǎn)構筑標準生產(chǎn)系統(tǒng)Belton Confidential ?? ? The key focus of a Lean factory is to estab