【正文】 r ownership ? Empower Operators ? Provide time for TPM activities ? Promote cooperation between Production and Maintenance 48 Total Productive Maintenance (TPM) Control 維護(hù)人員的角色 “專業(yè)的管理者” ? 有計(jì)劃的實(shí)施所有的定期保養(yǎng)并根據(jù)需要采取維修措施 。 ? 建立維護(hù)設(shè)備的保養(yǎng)記錄 ? 與操作員協(xié)同工作并提供技術(shù)支持 ? 執(zhí)行設(shè)備大修 ,綜合調(diào)試 ? 負(fù)責(zé)執(zhí)行一些特殊技能的任務(wù) ,風(fēng)險(xiǎn)安全性高的作業(yè) ? 促進(jìn) TPM 49 Total Productive Maintenance (TPM) Control Maintenance Role “The Specialized Caretakers” ? Perform all planned preventative maintenance and take corrective action as needed ? Use predictive tools such as vibration analysis, wear particle analysis, and thermography ? Document equipment maintenance history ? Cooperate with Operators and provide technical assistance ? Perform equipment overhaul, plex adjustments ? Provide special skill tasks, high safety risk tasks ? Promote TPM 50 Total Productive Maintenance (TPM) Control 操作員角色 “一線管理者” ? 清潔和缺陷檢查 ? 執(zhí)行基本的潤(rùn)滑 ,多點(diǎn)檢測(cè)的工作 ? 按照核準(zhǔn)清單的項(xiàng)目進(jìn)行定期保養(yǎng) ? 按計(jì)劃執(zhí)行日常清潔和整理 ? 識(shí)別剛剛發(fā)生的設(shè)備異常 ? 根據(jù)需要協(xié)助維護(hù)人員進(jìn)行維修 ? 執(zhí)行基本的調(diào)試工作 ? 改善提案 ? 促進(jìn) TPM 51 Total Productive Maintenance (TPM) Control Operator’s Role “The First Line Caretaker” ? Clean and inspect for defects ? Perform basic lubrication, multipoint inspection ? Perform Periodic Maintenance per approved List ? Perform routine cleaning and housekeeping as scheduled ? Identify equipment defects as they arise ? Assist Maintenance with repairs upon request ? Perform basic adjustments ? Suggest improvements ? Promote TPM 52 Total Productive Maintenance (TPM) Control 全面生產(chǎn)維護(hù)的七大步驟 1. 完成初始的機(jī)器清潔和檢查 2. 識(shí)別機(jī)器的缺陷和泄漏并加以標(biāo)示 3. 建立操作員及維護(hù)人員的定期檢測(cè)的 PM計(jì)劃 4. 指導(dǎo)操作員使用正確的保養(yǎng)方法 5. 指導(dǎo)維護(hù)人員使用正確的保養(yǎng)方法 6. 貫徹現(xiàn)場(chǎng) 5S管理和組織活動(dòng) 7. 監(jiān)控 OEE并鼓勵(lì)大家合作 53 Total Productive Maintenance (TPM) Control The 7 Steps of Total Productive Maintenance 1. Perform initial machine cleaning and inspection 2. Identify and tag machine defects and leaks 3. Develop Operator and Maintenance PM’s 4. Instruct Operators in proper PM techniques 5. Instruct Maintenance Staff in proper PM techniques 6. Implement 5S Housekeeping and Organization 7. Monitor OEE and encourage cooperation 54 Total Productive Maintenance (TPM) Control TPM 安全常識(shí) ? 遵守 /使用 ? 停工現(xiàn)場(chǎng)標(biāo)牌警示程序 ? 正確的起重方法 ? 用電安全操作規(guī)范 ? 勞保裝備 ? 手套 ? 工作鞋 ? 護(hù)目鏡 ? 防塵口罩 ? 耳塞 55 Total Productive Maintenance (TPM) Control TPM Safety Habits ? Follow/Use ? Lockout Tagout Procedure ? Proper Lifting Techniques ? Electrical Safety Guidelines ? Personal Protective Equipment ? Gloves ? Safety Shoes ? Goggles ? Respirators ? Hearing Protection 56 Total Productive Maintenance (TPM) Control TPM 步驟 1 初始的機(jī)器清潔和檢查 ? 目的 :識(shí)別需修理處并標(biāo)示缺陷 ? 執(zhí)行 : ? 徹底清潔機(jī)器 團(tuán)隊(duì)所有成員參與 ? 并將所有需要維修的項(xiàng)目標(biāo)示并記錄 57 Total Productive Maintenance (TPM) Control TPM Step 1 Initial Machine Inspection ? Purpose: To Identify needed repairs and tag defects ? Execution: ? Clean machine thoroughly – done by all team members ? Tag and record all repairs needed in a project notebook 58 Total Productive Maintenance (TPM) Control TPM 步驟 1 “現(xiàn)場(chǎng)活動(dòng)” ? 徹底的清潔工作包括 : ? 清除所有的碎屑及其他殘余物 ? 徹底地去除油污 ? 調(diào)節(jié)壓縮空氣 ? 更換過(guò)濾器 ,潤(rùn)滑劑等 ? 潤(rùn)滑移動(dòng)部件及接頭處 ? 清理不必要的使用工具 ,五金器具及備件等 ? “你的雙手肯定會(huì)臟兮兮的 !” 59 Total Productive Maintenance (TPM) Control TPM Step 1 “On Floor Activities” ? A Thorough Cleaning Includes: ? Removing all chips and other debris ? Thorough Degreasing ? Compressed air for controls ? Changing filters, lubricants, etc. ? Lubricating moving parts and joints ? Removing unnecessary tooling, hardware, supplies, etc. ? “You have to get your hands dirty!” 60 Total Productive Maintenance (TPM) Control TPM 步驟 1 “現(xiàn)場(chǎng)活動(dòng)” ? 維修項(xiàng)標(biāo)示色碼 ? 標(biāo)簽上須標(biāo)示的信息 : ? 機(jī)器的資產(chǎn)編號(hào) ? 機(jī)器位置及故障位置 ? 投入使用的日期及使用人 ? 機(jī)油 泄漏 —橙色 ? 冷卻液泄漏 —綠色 ? 空氣泄漏 – 黃色 ? 機(jī)器故障 – 粉紅色 ? 電氣問(wèn)題 藍(lán)色 61 Total Productive Maintenance (TPM) Control TPM Step 1 “On Floor Activities” ? Repair Tag Color Codes ? Information Needed on Tags ? Asset number of machine ? Location and relative position of defect on machine ? Name of originator and date ? Oil Leaks Orange ? Coolant Leaks Green ? Air Leaks Yellow ? Machine Defects Pink ? Electrical Problems Blue 62 Total Productive Maintenance (TPM) Control 關(guān)注 TPM清潔效果 降低停機(jī)時(shí)間 70% ? 之前 – 砂粒及碎屑很?chē)?yán)重 ? 無(wú)法調(diào)試 ? 運(yùn)行速度降低 ? 故障接連發(fā)生 ? 之后 – 跨功能工作的成果 ? 更換缺損的零部件 ? 調(diào)試校正 ? 恢復(fù)至設(shè)計(jì)速度且保持品質(zhì) 63 Total Productive Maintenance (TPM) Control Focused TPM Cleaning Effort Reduced Downtime by 70% ? Before – Severe Grit and Chips ? Out of adjustments ? Running at reduced speeds ? Constant breakdowns ? After – Crossfunctional Effort ? Replaced broken and missing parts ? Corrected the adjustment ? Returned to designed speed without incurring scrap 64 Total Productive Maintenance (TPM) Control TPM 步驟 2 修復(fù)機(jī)器的缺漏 ? 目的 :修復(fù)在步驟 1中找到的缺漏項(xiàng)目 ? 注意事項(xiàng) : ? 倡導(dǎo)者 /發(fā)起人需確保標(biāo)示出的問(wèn)題得到修復(fù) ? 實(shí)際的修復(fù)工作不必一定由團(tuán)隊(duì)成員來(lái)做 。 ? 生產(chǎn)主管須確保 PM工作的有效實(shí)施 71 Total Productive Maintenance (TPM) Control TPM Step 4 PM activity performed by the Operator ? Purpose: To detect early problems, provide the service interval, and insure 5S procedure is followed ? Considerations: ? Operator is responsible to perform PM’s as documented ? Production Supervisor to insure PM’s are effective 72 Total Productive Maintenance (TPM) Control TPM ? TPM使操作員更加獨(dú)立地自我管理和控制 。 ? 建立設(shè)備故障資料庫(kù) ? 收集并管理故障資料 ? 分析故障趨勢(shì)及形式 ? 定期展開(kāi)和發(fā)布總結(jié)報(bào)告 ? 包括用于定期回顧之用的會(huì)議議程報(bào)告 85 Total Productive Maintenance (TPM) Control Equipment Failures ? Experts estimate that 60% of machine breakdowns associated with moving parts are due to lack of or improper lubrication practices. ? Establish an equipment failure database ? Gather and manage failure information ? Analyze for trends and patterns ? Develop and issue periodic summary reports ? Include reports as a meeting agenda for regular review