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1、1,Total Productive Maintenance,OFFICE 办公室,2,Process Certification,QCPC,Root Cause / Corrective Action,Set-Up Reduction,Standard Work,Mistake Proofing,Market Feedback Analysis,6S,Quality Clinic Activity,Total Productive Maintenance ACE Office Qualifying Level,TPM,3,程序验证,全面性生产 维护,质量诊断程序 图表,根本原因 修正行动,减
2、少生产 准备,标准化 作业,防误措施,市场反馈 分析,6S,质量诊断 活动,全面生产性维护 ACE 办公室合格水平,4,Total Productive Maintenance is an equipment management strategy that improves equipment efficiency. 全面生产性维护是一种设备管理策略以提高设备效率。 Or, in other words. Treating the equipment like it is your own! 或者，换句话说. 对待设备就象它是你自己的 一样！,TPM 全面生产性维护,5,TPM Key Co
3、ncept TPM的重要概念,Left neglected. Equipment Breaks Down 如果不重视设备很快就会坏,TPMs focus is to prevent problems before equipment breaks. TPM 的焦点是要在设备出故障以前防止问题出现。,In the past, maintenance focusedon fixing equipment after it broke. 过去，维护工作总是集中在设备坏了 以后对其进行修理。,6,Total Productive Maintenance is a New Way of Working全
4、面生产性维护是一种全新的工作方式,TPM Attitude: TPM态度： “We are all responsible for our equipment.” “我们所有人对我们的设备负责。”,Old Attitude: 过去的态度： “I operate, you fix.” “作，你修理。” “I fix, you design.” “我处理，你设计。” “I design, you operate.” “我设计，你作。”,7,A failure is just the tip of the iceberg! 故障只是冰山的一个小尖！,Hidden Defects 隐藏的问题,Fail
5、ures 故障,Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw materials,surface damage, cracking, overheating, vibration, noise, and other abnormalities. 磨损、松驰、泄露、灰尘、污垢、腐蚀变形、原材料粘黏、表面磨损、裂缝、过热、震动、噪音及其它不正常现象。,Tip of the Iceberg冰山的顶端,8,Typical Causes of Equipment Breakdown
6、典型的设备故障原因,Failure to replace toner 更换墨盒失败,I wonder whats going to fail next? 我想下面还会出什么 问题呢？,Dirt and contamination 灰尘和污染,Out of paper 缺纸,9,TPM Benefits TPM的益处,Reduced maintenance costs 减少维护费用 Breakdown maintenance is 10 times more costly than planned maintenance 故障维修费用是有计划进行维护费用的10倍以上 Enhanced safet
7、y 提高安全性 Find exposed wires, open belts, missing guards, loose hardware 发现暴露在外的电线、松开的安全带、缺少防护、松开的部件 Reduced waste 减少浪费 Prevents loss of lubricant, compressed air 防止润滑油、压缩空气的浪费 Improved quality 提高品质 Equipment more capable of holding tolerance 设备抗性增强 Less down time, longer life缩短停工时间，寿命更长,10,TPM Qualif
8、ying Criteria (Business Process/Office),ACE Element Awareness Training for all employees Equipment assessment A,B & C PM plan for 100% of category “A” equipment Whats Ahead BRONZE TPM CRITERIA Implement PM Plan Track downtime history for vital machines Process Management Identify Key Processes Ident
9、ify Waste Elimination Opportunities,11,TPM 合格标准 (商业程序/办公室),ACE 内容认知培训，针对所有员工 A,B & C类设备评估 所有“A”类设备的PM计划 前面是什么？ 铜牌TPM标准 执行PM计划 追溯重要机器的停工历史记录 程序管理 确定关键程序 确定浪费消减方法,12,Sullair Safety Lockout Program Procedure寿力安全设备锁定计划程序,Lockout Procedures: 锁定程序： Actions necessary to lockout a power source of any machin
10、e to be repaired, serviced or set-up, where unexpected motion, or an electrical or other energy source, would cause personal injury or equipment damage. 在任何机器的电源需要修理、维护或准备的地方都必须进行锁定，否则意外的动作或其它电源将会引起人身的伤害或设备的损坏。,Lockout Tag: 锁定标签,13,WARNING 警告,NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE. 决不要从它人处接受锁定设备的钥匙。
11、 THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOCK OR TAG. 唯有经授权负责运用锁或标签的人员可以拿掉该锁或标签。,Lockout/Tagout Review: 锁定/标识检查,14,ACTION ITEM 1: Assess All Equipment活动内容1：评估所有设备,By “Equipment” we mean any machine that was a capital expense and has a deprec
12、iative value. Or any machine that is important to your cell. 所谓“设备”是指任何花费了资金并会贬值的机器。或任何对你的部门重要的机器。 We Categorize all Equipment based on how Unique and Critical it is to ensure we focus attention on the right equipment first. Pay special attention to bottleneck equipment. 我们根据设备的独特性和重要性对所有设备进行分类，以确保我
13、们的注意力首先放在正确的设备上。对瓶颈设备给予特殊的关注。,15,?,ACTION ITEM 1: Assess All Equipment(cont.) 活动内容1：评估所有设备（待续）,Category A: Critical equipment for which an alternate machine is not feasible, because: A类：不能用其它设备替代的关键设备，因为： No alternate exists, or 无替代设备，或 The alternate is usually unavailable due to utilization, or 该替代
14、设备通常正被使用而不能获得，或 It would be too costly/time consuming to transition to the alternate 太贵/需花太多时间进行替换 Category C: Equipment for which it is relatively easy to find a replacement or alternate C类：相对容易用其它设备替代的设备 Includes most off-the-shelf equipment 包括最常用的设备 Typically cost $2,500 费用低于$2,500 Standard spare
15、 parts (like drive motors) are available off-the-shelf 可获得的常用标准备件（如驱动马达） Category B: All other equipment/machines B类：所有其它设备/机器,16,In addition to machine category, create a table listing all machines and additional categories, such as: 除了机器分类，还应作一表格列出所有机器和附加类别，如： Item description/ID number 物品描述/ID号 C
16、ategory 种类 Item Owner 物品主人 Identify equipments title holder and a “local” owner if appropriate 确定设备名义上的拥有者及一“本地”主人，如有必要的话 Department managers signature 部门经理的签名,ACTION ITEM 1: Assess All Equipment(cont.) 活动内容1：评估所有设备（待续）,17,Example: Office Equipment Assessment Worksheet,18,范例: 办公室设备评估 工作表,19,ACTION ITEM 2: PM Plan on 100% “A”活动内容2：针对所有A类机器的PM计划,Operator PM defined for 100% of Category A machines. 为所有A类机器制定作员PM D
