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1、全面生产维护 (TPM),TPM TPM 团队组织 设备综合利用率OEE TPM 活动步骤,RD011202,Total Productive Maintenance (TPM),TPM TPM Team Organization Overall Equipment Effectiveness TPM Phases,RD011202,Total Productive Maintenance (TPM),3,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
2、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 一种源头监控和校正的先发系统;
3、 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),8,Whats in It for Me?,Optimized process operations and maintenance A method to replace the traditional approach of detecting and correcting faulty conditions as they occur A proactive system which monitors and corrects causes An opera
4、tions strategy based on understanding the cause and effect system affecting the major contributors to process performance,Total Productive Maintenance (TPM),9,全面生产维护 (TPM),定义: 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),10,Total Productive Maintenance (TPM),TPM Defin
5、ition A common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance.,Total Productive Maintenance (TPM),11,TPM,通过实施预防实现设备零故障和零缺陷; 预防工作将立足于以下方面: 维持正常的生产条件 及早发现异常 快速反应,Total Productive Maintena
6、nce (TPM),12,TPM,Achieve zero equipment breakdowns and zero defects through prevention Establish prevention by Maintaining normal conditions Early detection of abnormalities Quick response,Total Productive Maintenance (TPM),13,传统的反应式维护,维修部门 “我们只管修理” 执行所有的维修作业 往往是一旦设备发生故障充当救火员的角色; 负责定购和保管所有的工具,备件等物资;
7、 实施定期检修,生产部门 ”我们只管使用“ 通常不作任何维护活动 一旦设备出现故障就与维修部门联系 维修作业中只能停工; 一直用到坏了为止,Total Productive Maintenance (TPM),14,Traditional Approach“Re-Active Maintenance”,Maintenance “WE FIX” Perform all maintenance activities Perform “Fire Fighting” maintenance when a machine breakdown occurs Order and administer all
8、 tooling, supplies, etc. Perform Preventive Maintenance,Manufacturing “WE OPERATE” Generally does not perform any maintenance activities Contacts maintenance when a machine breakdown occurs Inactive during maintenance activities “Run it till it breaks”,Total Productive Maintenance (TPM),15,主要概念,定期保养
9、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. 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.根据可视信号或检测技术的情况来实施保养以防止设备发生故障. 振动分析 激光探测 超声波检测 发电机测试 热感应 油况分析,Total Productive Maintenance (TPM),16,Key Definitions,Preventive Maintenance is a time or usage based method of maintaining equipment. Maintenance activiti
10、es are performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occurring. PM Schedules,Predictive Maintenance is a situation based method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagnosti
11、c techniques to prevent equipment breakdowns from occurring. Vibration Analysis Laser Measuring Ultrasound Generator Testing Thermography Oil Analysis,Total Productive Maintenance (TPM),17,现状分析和团队组织,评估当前的操作条件: 机器利用率,生产率等; 维修费用 (配件和人工) 对实现TPM的各项工作进行优先次序 评估潜在TPM倡导者及团队成员的实力 挑选TPM倡导者及团队成员 建立初始的实施专门小组 确定
12、团队目标,Total Productive Maintenance (TPM),18,Present State Analysisand Team Organization,Assess Current Operating Conditions Machine utilization, productivity, etc. Maintenance repair costs (parts and labor) Prioritize order of TPM efforts Assess capabilities of potential TPM Champions and Team Member
13、s Select TPM Champion and Team Members Establish initial kick-off workshop Establish team goal,Total Productive Maintenance (TPM),19,典型的设备评价指标,利用率: 设备实际运转时间与总的可利用时间的比率; = 实际运行时间/可运行时间 效率: 实际产量与标准产量的比率 = (实际产量/小时)/(标准产量/小时) 产出: 用一特定时间段的产量来衡量 = 磅/小时, 件数/小时,Total Productive Maintenance (TPM),20,Typical
14、 Operational Process Measurements,Utilization: The ratio of equipment actual operating time to the total available operating time = Actual Operating Time/Available Time Efficiency: The ratio of actual product produced to a standard = (Actual Parts/Hour)/(Standard Part/Hour) Output: Measure of output
15、 over a specified time period = lbs/hr, pieces/hr,Total Productive Maintenance (TPM),21,设备综合利用率OEE,设备综合利用率（OEE）是衡量一台设备按计划速度生产出合格产品的时间占全部时间的百分比.,Total Productive Maintenance (TPM),22,Overall Equipment Effectiveness,Overall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of
16、 equipment is producing quality product at the designed rate.,Total Productive Maintenance (TPM),23,OEE分解:六大浪费,故障及轻微故障 使设备中断运行的时间超过10分钟的故障或者中断时间少于10分钟的轻微故障. 设置时间浪费 任何与设备调整,装配,清洁相关的作业.,机器空转浪费 设备在运转却没有用来生产产品所耗用的时间. 速度浪费 由于设备或产品的异常造成设备以低于标准速度或所设定的速度运转.,品质原因浪费 为确保设备产出品的品质而采取相关的作业(过程中检查). 返工浪费 用于返修产品或生产出报废产品所耗用的时间.,Total Productive Maintenance (TPM),24,OEE Breakdown: The Six Big Losses,Breakdowns and Minor Stoppages Malfunctions causing equipment to stop processing greater than 10 minutes (b
