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1、全面生产维护 (TPM) uTPM uTPM 团队组织 u设备综合利用率OEE uTPM 活动步骤 RD011202 Total Productive Maintenance (TPM) uTPM uTPM Team Organization uOverall Equipment Effectiveness uTPM Phases RD011202 精益6 过程改善流程 分析控制改进 定义 选定题目 列出客户 从顾客之声中列出关建需 求 定出项目焦点和重要指标 完成 PDF 测量 绘制业务流程图 绘制价值流程图 制定数据收集计划 测量系统分析 收集数据 过程能力分析 分析 提出关键因子 区分关
2、键因子 验证关键因子 评枯每个关键因子对结果 的影响 量化机会 根本原因排序 寻找根本原因针对关键因 子 改进 关键因子确认 发掘潜在的解决方法 选择方案 优化方案 实行方案 控制 过程变革和控制 制定控制计划 计算最终财务 过程指标 项目过渡给未来项目管理者 项目鉴 别 转化机会 测量 定义 项目编号工具 项目定义表 净现值分析 内部回报率分析 折算现金流分析 PIP管理过程 RACI Quad 表 过程图 价值分析 脑力风暴 投票归类法 柏拉图 因果图/鱼骨图 FMEA 查检表 运行图 控制图 量具 R n消除导致设备故障的因素; n使设备的养护清洁更易达成; n用预测性保养作为一种检测工
3、具; n实施维护审查 Total Productive Maintenance (TPM) Learning Objectives uLearn a method to: nIntegrate operational productivity factors applicable in process industries in a single comprehensive measurement nEliminate factors contributing to equipment failure nImprove accessibility for cleaning and mainta
4、ining equipment nUse predictive maintenance as a diagnostic tool nImplement maintenance audits Total Productive Maintenance (TPM) 个人学习意义 u流程作业和保养最优化 u一种替代传统的在故障发生时检测并修复的方法; u一种源头监控和校正的先发系统; u一种基于对影响过程性能的主要因素其因果系统的理解工作 策略; Total Productive Maintenance (TPM) Whats in It for Me? uOptimized process oper
5、ations and maintenance uA method to replace the traditional approach of detecting and correcting faulty conditions as they occur uA proactive system which monitors and corrects causes uAn operations strategy based on understanding the cause and effect system affecting the major contributors to proce
6、ss performance Total Productive Maintenance (TPM) 全面生产维护 (TPM) 定义: u一种用于监控操作,设备保养,消除计划外停机,和提高作业与 保养协调程度的常识性方法。 Total Productive Maintenance (TPM) Total Productive Maintenance (TPM) TPM Definition uA common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and
7、improve the level of cooperation between Operations and Maintenance. Total Productive Maintenance (TPM) TPM u通过实施预防实现设备零故障和零缺陷; u预防工作将立足于以下方面: n维持正常的生产条件 n及早发现异常 n快速反应 Total Productive Maintenance (TPM) TPM uAchieve zero equipment breakdowns and zero defects through prevention uEstablish prevention
8、by nMaintaining normal conditions nEarly detection of abnormalities nQuick response Total Productive Maintenance (TPM) 传统的反应式维护 维修部门 “我们只管修理” n执行所有的维修作业 n往往是一旦设备发生故障充 当救火员的角色; n负责定购和保管所有的工具, 备件等物资; n实施定期检修 生产部门 ”我们只管使用“ n通常不作任何维护活动 n一旦设备出现故障就与维修 部门联系 n维修作业中只能停工; n一直用到坏了为止 Total Productive Maintenanc
9、e (TPM) Traditional Approach “Re-Active Maintenance” Maintenance “WE FIX” nPerform all maintenance activities nPerform “Fire Fighting” maintenance when a machine breakdown occurs nOrder and administer all tooling, supplies, etc. nPerform Preventive Maintenance Manufacturing “WE OPERATE” nGenerally d
10、oes not perform any maintenance activities nContacts maintenance when a machine breakdown occurs nInactive during maintenance activities n“Run it till it breaks” Total Productive Maintenance (TPM) 主要概念 定期保养是一种基于时间长短或 使用状况对设备进行检修的方法. 在指定时间或在使用空档间对设 备实施检修作业以防止设备发生 故障. n定期保养计划 预测性保养是一种基于设备状态 的维护方法.根据可视
11、信号或检测 技术的情况来实施保养以防止设 备发生故障. n振动分析 n激光探测 n超声波检测 n发电机测试 n热感应 n油况分析 预测性保养预测性保养定期保养定期保养 Total Productive Maintenance (TPM) Key Definitions Preventive Maintenance is a time or usage based method of maintaining equipment. Maintenance activities are performed on equipment based on defined time and/or usage
12、 intervals to prevent equipment breakdowns from occurring. nPM Schedules Predictive Maintenance is a situation based method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring. nV
13、ibration Analysis nLaser Measuring nUltrasound nGenerator Testing nThermography nOil Analysis Predictive MaintenancePredictive MaintenancePreventive MaintenancePreventive Maintenance Total Productive Maintenance (TPM) 现状分析和团队组织 u评估当前的操作条件: n机器利用率,生产率等; n维修费用 (配件和人工) n对实现TPM的各项工作进行优先次序 u评估潜在TPM倡导者及团队
14、成员的实力 u挑选TPM倡导者及团队成员 n建立初始的实施专门小组 n确定团队目标 Total Productive Maintenance (TPM) Present State Analysis and Team Organization uAssess Current Operating Conditions nMachine utilization, productivity, etc. nMaintenance repair costs (parts and labor) nPrioritize order of TPM efforts uAssess capabilities of
15、 potential TPM Champions and Team Members uSelect TPM Champion and Team Members nEstablish initial kick-off workshop nEstablish team goal Total Productive Maintenance (TPM) 典型的设备评价指标 u利用率: 设备实际运转时间与总的可利用时间的比率; n= 实际运行时间/可运行时间 u效率: 实际产量与标准产量的比率 n= (实际产量/小时)/(标准产量/小时) u产出: 用一特定时间段的产量来衡量 n= 磅/小时, 件数/小时
16、 Total Productive Maintenance (TPM) Typical Operational Process Measurements uUtilization: The ratio of equipment actual operating time to the total available operating time n= Actual Operating Time/Available Time uEfficiency: The ratio of actual product produced to a standard n= (Actual Parts/Hour)/(Standard Part/Hour) uOutput: Measure of output over a specified time period n= lbs/hr, piece
