【正文】 r ownership ? Empower Operators ? Provide time for TPM activities ? Promote cooperation between Production and Maintenance 48 Total Productive Maintenance (TPM) Control 維護人員的角色 “專業(yè)的管理者” ? 有計劃的實施所有的定期保養(yǎng)并根據(jù)需要采取維修措施 。 ? 建立維護設備的保養(yǎng)記錄 ? 與操作員協(xié)同工作并提供技術支持 ? 執(zhí)行設備大修 ,綜合調(diào)試 ? 負責執(zhí)行一些特殊技能的任務 ,風險安全性高的作業(yè) ? 促進 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)行基本的潤滑 ,多點檢測的工作 ? 按照核準清單的項目進行定期保養(yǎng) ? 按計劃執(zhí)行日常清潔和整理 ? 識別剛剛發(fā)生的設備異常 ? 根據(jù)需要協(xié)助維護人員進行維修 ? 執(zhí)行基本的調(diào)試工作 ? 改善提案 ? 促進 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)維護的七大步驟 1. 完成初始的機器清潔和檢查 2. 識別機器的缺陷和泄漏并加以標示 3. 建立操作員及維護人員的定期檢測的 PM計劃 4. 指導操作員使用正確的保養(yǎng)方法 5. 指導維護人員使用正確的保養(yǎng)方法 6. 貫徹現(xiàn)場 5S管理和組織活動 7. 監(jiān)控 OEE并鼓勵大家合作 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 ? 遵守 /使用 ? 停工現(xiàn)場標牌警示程序 ? 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 初始的機器清潔和檢查 ? 目的 :識別需修理處并標示缺陷 ? 執(zhí)行 : ? 徹底清潔機器 團隊所有成員參與 ? 并將所有需要維修的項目標示并記錄 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)場活動” ? 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 ? 更換過濾器 ,潤滑劑等 ? 潤滑移動部件及接頭處 ? 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)場活動” ? 維修項標示色碼 ? 標簽上須標示的信息 : ? 機器的資產(chǎn)編號 ? 機器位置及故障位置 ? 投入使用的日期及使用人 ? 機油 泄漏 —橙色 ? 冷卻液泄漏 —綠色 ? 空氣泄漏 – 黃色 ? 機器故障 – 粉紅色 ? 電氣問題 藍色 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 關注 TPM清潔效果 降低停機時間 70% ? 之前 – 砂粒及碎屑很嚴重 ? 無法調(diào)試 ? 運行速度降低 ? 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 ? 恢復至設計速度且保持品質(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 修復機器的缺漏 ? 目的 :修復在步驟 1中找到的缺漏項目 ? 注意事項 : ? 倡導者 /發(fā)起人需確保標示出的問題得到修復 ? 實際的修復工作不必一定由團隊成員來做 。 ? 生產(chǎn)主管須確保 PM工作的有效實施 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使操作員更加獨立地自我管理和控制 。 ? 建立設備故障資料庫 ? 收集并管理故障資料 ? 分析故障趨勢及形式 ? 定期展開和發(fā)布總結(jié)報告 ? 包括用于定期回顧之用的會議議程報告 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