【正文】 lish a process system which is Fast, Flexible Predictable 精益工廠的核心目的是建立一個快速的 ﹑ 靈活的和可預(yù)見的系統(tǒng) ? All equipment sets don?t perform at a same fixed rates all the time. Equipment sets perform with variable standards of performance 所有的設(shè)備不會一直以同樣的速度工作 ﹐ 它們有自己的變異 ? Each piece of equipment in a progressively arranged line is dependant on the event of other equipment in the line. This is called statistical fluctuation of dependent events 每臺設(shè)備的產(chǎn)能依存于這條生產(chǎn)線其它設(shè)備的運行狀況 ﹐ 這叫做獨立事件的統(tǒng)計波動 Statistical fluctuation 統(tǒng)計波動 Belton Confidential ?? When each piece of equipment is not producing at a predictable tact time the effects are 當(dāng)每臺設(shè)備不以妳期望的節(jié)拍生產(chǎn)時會導(dǎo)致 : High inventory holding at random locations to cushion downtime 庫存會隨機的堆積在工序中來應(yīng)付停機 Non linear flow of parts 產(chǎn)品不會直線性的連續(xù)流動 Bottlenecks starve for parts or are not optimised 瓶頸工序挨餓或者優(yōu)化不夠 Therefore you need to reduce the variability by improving equipment performance to improve the productivity(UPMH)rather than adding WIP or investing on capital 所以提高生產(chǎn)力 , 你必須降低設(shè)備的變異 , 而不是增加 WIP或者購買設(shè)備 ﹒ Statistical fluctuation 統(tǒng)計波動 Belton Confidential ?? Equipment Losses Understanding 理解設(shè)備損失 Belton Confidential ?? The seven big losses 七大損耗 Down Time: 停機 ?Equipment failure(breakdowns)設(shè)備故障 ?Preventive Maintenance 預(yù)防維護(hù) ?Setup and adjustment 切換和調(diào)整 Speed Losses: 速度損失 ?Idling and minor stoppages 點點停 ?Reduced speed 速度低下 Defect: 不良 ?Process defects due to scrap and quality 過程不良 運行中產(chǎn)生的不良品 ?Reduced yield machine startup 開機品質(zhì)低下 啟動產(chǎn)生的不良品 M a j orBre a kdow nM i norBre a kdow nS e t up T i m eQ ua l i fi c a t i onT i m eM a j or P MM i nor P MO t he rIdl e N o W IPIdl e N oO p e ra t orIdl e Cons um a bl e sIne ffe c t i veP roc e s s i ngT i m e S p e e dIne ffe c t i veP roc e s s i ngT i m e Q ua l i t yE ffe c t i veP roc e s s i ngT i m eL oa d /U nl oa dBelton Confidential ?? TPM Equipment Improvement TPM 設(shè)備改善 The tools which are used to improve equipment lossess include 用來改善設(shè)備損耗的工具有 : ?Set Up Time Reduction 快速切換 ?Error Proofing 防錯法 ?5S and Task Transfer 5S和責(zé)任轉(zhuǎn)移 ?KANBAN Drum Buffer Rope 看板 ﹐ 鼓 － 緩沖器 － 繩子 ?Equipment FMEA Six Sigma ?Visual Control System 目視管理 ?Standardised Work 標(biāo)準(zhǔn)化作業(yè) Belton Confidential ?? TPMApproach 步驟 Analysis Correction Prevention 分析 預(yù)防 改良 Belton Confidential ?? Analysis 分析 Solving maintenance problems requires indepth understanding of equipment performance 解決維修問題需要對設(shè)備的性能有深刻的理解 Necessary to truly understand cause effect 需要真正理解因果關(guān)系 ?What information do you currently have to understand equipment issues 目前你有哪些信息來了解設(shè)備問題 ? ?Maintenance records 維修記錄 ?Daily performance records 每日生產(chǎn)記錄 ?Quality records 品質(zhì)記錄 ?Operator experience 員工經(jīng)驗 ?Direct observation 直接觀察 ?Equipment vendor data 設(shè)備廠家資料 Belton Confidential ?? Analysis 分析 設(shè)備維護(hù)應(yīng)具備的基本用語基本用語 含義 內(nèi)容 基本用語 含義 內(nèi)容穩(wěn)定性因機能低下或機能停止而不能工作( M T B F越長越好)故障發(fā)生頻率不良發(fā)生頻率速度穩(wěn)定點點停少操作性運轉(zhuǎn)設(shè)備或切換能正確迅速進(jìn)行夾具, 模具更換容易, 調(diào)整容易按鈕操作易( 高度, 配置, 數(shù)量, 形狀, 顏色等)搬運, 取拿容易省資源性運轉(zhuǎn)設(shè)備必要能源,油等資源的消耗低資源的單位消耗成本降低資源再利用程度安全性 不給人類直接危害處理故障, 瞬間停止, 不良等例外作業(yè)少旋轉(zhuǎn), 活動部分暴露少沒有突出物, 障礙物維護(hù)性能短時間并容易地進(jìn)行清掃, 注油, 點檢等維護(hù)活動M T T R 越短越好迅速發(fā)現(xiàn)故障部位大修容易注油, 換油容易快速恢復(fù)機能并可以確認(rèn)部件更換容易末端潤滑油確認(rèn)容易品質(zhì)保証容易精度測定容易發(fā)生源, 飛散部位最少化清掃, 注油, 點檢容易Belton Confidential ?? Correction 改良 A process to ensure that the equipment is being used correctly(manufacturing technology) and managed correctly(human functions) 確保設(shè)備正確地使用和正確地管理 Design reliability 設(shè)計可靠性 Equipment build reliability 制造可靠性 Installation reliability 安裝可靠性 Operation reliability 操作可靠性 Maintenance reliability 維修可靠性 The detection and restoration of abnormalities to sustain the