【正文】 員參與 Total employee involvement ? 提高機器效率 , 滿足節(jié)拍 速度 Achieve Takt Rate at the highest machine effectiveness 8 8 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB TPM與傳統(tǒng)保養(yǎng) TPM vs. Traditional Maintenance 每班 8小時 8 hr shift 有效時間 = 7小時 40分 Effectiveness = 7 hrs 40min 工人開會 : 10分鐘 Operator Meeting 10 min 10 min 設備清潔與潤滑 : 10分鐘 Equipment cleaning Lubrication 傳統(tǒng) 生產(chǎn) 班次 Traditional Operating Shift : 實行 TPM的班次 TPM Shift : 本班開始 Shift Start 品質(zhì)問題 Quality 暫停 Minor Stoppages 故障停機 Breakdown 調(diào)整 Adjustment 本班結(jié)束 Shift End 每班 8小時 8 hr shift 有效時間 = 6小時 Effectiveness = 6 hrs 8 10 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. LeanSigma174。, LeanStrategy174。 2023 TBM Consulting Group, Inc. All Rights Reserved. LeanSigma174。, LeanStrategy174。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB TPM五大支柱 The 5 Pillars of TPM 自主保養(yǎng) Autonomous Maintenance 計劃保養(yǎng) Planning Maintenance 預防工程 Preventive Engineering 品質(zhì) Quality 教育與行動 Education Practice 8 14 169。評價是否需要進行更多改善活動 , 制定更高的目標 , 或需要更換專職隊員 Check results to improvement goals monthly. Evaluate need for additional kaizen activity, setting more aggressive goals, or modifying permanent team members. Time Based Management P – SKB 169。, The Perfect Engine174。, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc. 自主保養(yǎng) Autonomous Maintenance 8 16 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 自主保養(yǎng)五步法 5 Steps to Autonomous Maintenance 1. 進行基本清潔活動 Perform basic cleaning 2. 根除骯臟污染源頭 Eliminate sources of dirt and contamination 3. 建立清潔潤滑標準 Establish cleaning and lubrication standards 4. 教會設備基本檢查 , 進行自主設備檢查 Teach general inspection of equipment and Perform autonomous equipment inspection 5. 培養(yǎng)整齊有序習慣 Instill orderliness and anization 8 18 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 維修人員作用 Roles of Maintenance Personnel ? 設備保養(yǎng) Maintain Equipment ? 檢驗 (拆卸 ) Inspect (disassembly) ? 計劃保養(yǎng) Planned overhauls ? 預防保養(yǎng) Preventive maintenance ? 教導工人學會特定保養(yǎng)工作 Teach selected maintenance tasks to operators ? 設備改善 Improve Equipment ? 支持可靠性及可維修性改善 Support RM improvement ? 實施預測技術 Implement predictive technologies ? 糾正設計不足 Correct design weaknesses ? 搞好供方合作 Partner with vendors 8 20 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 設備檢查表 Equipment Inspection Checklist ? 液壓系統(tǒng) Hydraulics ? 油箱裝夠油了嗎 ? Is the oil tank filled to the specified level? ? 油泵發(fā)出異常噪音嗎 ? Is the pump emitting any abnormal noises? ? 卸荷閥、減壓閥、節(jié)流閥防松螺母上緊了嗎 ? Are locknuts tight on relief, reducing and throttle valves? ? 卸荷閥、控制裝置運作正常嗎 ? Are relief valves and controls operating correctly? ? 高壓管路連接變形或磨損了嗎 ? Any strain or wear in high pressure hose connections? ? 電器系統(tǒng) Electrical ? 行程開關杠桿能夠完全接觸嗎 ? Do limit switch bars strike fully? ? 信號燈、指示燈遺失或燒壞了嗎 ? Any missing or burned out pilot or indicator lights? ? 配電盤、電器箱有無線路圖 ? Are there wiring diagrams in the control panels or electrical boxes? ? 有無多余的、損壞的、壓壞的電線或軟管 ? Any unnecessary, damaged or dented wires or flexible tubing? 8 22 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 設備檢查表 Equipment Inspection Checklist ? 螺母螺栓 Nuts and Bolts ? 登記記號允許松緊度檢查嗎 ? Do registration marks permit tightness checks? ? 螺母螺栓型號及尺寸正確嗎 ? Are nuts and bolts of the suitable types or sizes used? ? 墊片尺寸正確 , 且類型相配嗎 ? Are washers of proper size, and are they consistently used? ? 螺栓有從螺母凸出 2~3圈螺紋嗎 ? Do bolts protrude 2 – 3 threads from the nuts? ? 氣動系統(tǒng) Pneumatics ? 截止閥及球閥漏氣嗎 ? Any stop valve, ball valve leaks? ? 有壞了或多余的手把嗎 ? Any broken or unnecessary handles? ? 已關閉的閥仍有氣流嗎 ? Does any air flow through closed valves? ? 有任何不必要的裝置或喉管嗎 ? Are any unnecessary devices, hoses or pipes present? ? 所有喉管都整齊及易于識別嗎 ? Are pipes and hoses orderly and readily identifiable? ? 壓力表指示的都是正確設定的壓力嗎 ? Do pressure gauges clearly indicate the correct set pressure? 8 24 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 消滅臟污源頭 Eliminate Sources Of Dirt Contamination 臟污原因 Causes of Contamination: ? 發(fā)生液體泄漏 Fluid leaks ? 碎片容器很差 Poor chip containment ? ５Ｓ工作不佳 Poor 5S practices ? 工作區(qū)有濺灑 Work area spills ? 過濾性能不好 Poor filtration ? 沒有清潔標準 No cleaning standards ? 無工作自豪感 Poor work pride ? 環(huán)境問題惡劣 Environment 8 26 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 重點訓示 OnePoint Lesson 目的 /范圍 : 根據(jù) 3600路線檢查單脂具體檢查步驟制定詳細的工作指示 責任 : 工人 安全 : 標準的工人保護設備 : 防護眼鏡 , 聽覺保護用具 , 手套 , 鋼頭鞋 工作指示 第 1步 : 本工作指示用于與 3600路線檢查單有關的工作 第 2步 : 本工作指示用于 3600噸沖壓機周圍的檢查工作 3~5 第 3步 : 檢查模具加熱爐溫度及設定值。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 進行自主保養(yǎng)檢查 Perform Autonomous Maintenance Inspection ? 制定詳細的培訓計劃 Develop in depth training program ? 對工人就以下內(nèi)容進行培訓： Train operators in: ? 潤滑作用 /粘性分析 Lubrication/ Viscosity Analysis ? 氣動系統(tǒng) Pneumatics ? 液壓系統(tǒng) Hydraulic ? 電氣系統(tǒng) Electrical systems ? 驅(qū)動系統(tǒng) Drive systems ? 修改目前的重點訓示 , 加入檢驗檢查工作 Revise existing onepoint lessons to include inspection checks 8 29 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 整潔與條理 Organization Orderliness 8 31 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 020406080100問題公報 Problem Newspaper 問題公報 Problem Newspaper 生產(chǎn)保養(yǎng)完成率 PM Completion Ratio 保養(yǎng)小組目視控制 Maintenance Group Visual Control 8 33 169。 2023 TBM Consulting Group, Inc. All Rights Reserved. LeanSigma174。, LeanStrategy174。 2023 TBM Consulting Group, Inc. All Rights Reserved. P – SKB 進行 TPM基礎