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1、Total Productive MaintenanceOFFICE 办公室1Process CertificationQCPCRoot Cause / Corrective ActionSet-Up ReductionStandard WorkMistake ProofingMarket Feedback Analysis6SQuality Clinic ActivityTotal Productive Maintenance ACE Office Qualifying Level TPM2程序验证全面性生产 维护质量诊断程序 图表根本原因 修正行动减少生产 准备标准化 作业防误措施市场反馈
2、 分析6S质量诊断 活动全面生产性维护 ACE 办公室合格水平 3Total 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4TPM Key Concept TPM的重要概念 Left neglected. Eq
3、uipment 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 focused on 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。5Total Productive Maintenance is a New Way of Working 全面生产性维护是一种全新的工作方式TPM Attitude:TPM A
4、ttitude: TPMTPM态度：态度： “We are all responsible for our “We are all responsible for our equipment.”equipment.” “ “我们所有人对我们的设备负责。我们所有人对我们的设备负责。” ”Old Attitude:Old Attitude: 过去的态度：过去的态度： “I operate, you fix.”“I operate, you fix.” “ “作，你修理。作，你修理。” ” “I fix, you design.”“I fix, you design.” “ “我处理，你设计。我处理
5、，你设计。” ” “I design, you operate.”“I design, you operate.” “ “我设计，你操作。我设计，你操作。” ”6Hidden Defects 隐藏的问题Failures 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
6、、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7Component Failure 部件失灵Typical Causes of Equipment Breakdown 典型的设备故障原因Failure to replace toner 更换墨盒失败 Paper jam 卡纸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8TPM Benefits TPM的益处 Reduced
7、 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 safety 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
8、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9TPM Qualifying Criteria (Business Process/Office)3ACE Element Awareness Training for all employees oEquipment assessment A,B & C oPM plan for 100% of category “A” equipment Wha
9、ts AheadoBRONZE TPM CRITERIA oImplement PM Plan oTrack downtime history for vital machines oProcess Management oIdentify Key Processes oIdentify Waste Elimination OpportunitiesQualifyingAwareness & Baseline10TPM 合格标准(商业程序/办公室)3 ACE 内容认知培训，针对所有员工 o A,B & C类设备评估 o 所有“A”类设备的PM计划 前面是什么？ o 铜牌TPM标准 o 执行PM
10、计划 o 追溯重要机器的停工历史记录 o 程序管理 o 确定关键程序 o 确定浪费消减方法合格认知 & 基线11Sullair 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 machine to be repaired, serviced or set-up, where unexpected motion, or an electrical or other energy source, woul
11、d 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12WARNING WARNING 警告警告NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE. 决不要从它人处接受锁定设备的钥匙。THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE
12、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13ACTION 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 depreciative 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 Ca
13、tegorize 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。14?ACTION ITEM 1: Assess All Equipment(cont.)活动内容1：评估所有设备（待续）Category A:Cat
14、egory A: Critical equipment for which an alternate machine is not feasible, because: A A类：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
15、进行替换 Category C:Category C: Equipment for which it is relatively easy to find a replacement or alternate C C类：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 parts (like drive motors) are available off-the-shelf 可获得的常用标准备件（如驱动马达） Catego
16、ry B:Category B: All other equipment/machines B B类：类：所有其它设备/机器 15In 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 Category 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 s
