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1、全员生产保养 Total Productive Maintenance,目录 Table of Contents,TPM概略 TPM Overview TPM目的 The Aim of TPM TPM流程 TPM Process 自主保养 Autonomous Maintenance 计划保养 Planned Maintenance 预防工程 Preventive Engineering 教育与行动 Education & Practice 保证质量 Insured Quality TPM改善活动 TPM Kaizen Activities TPM活动进阶 Advanced TPM Activ
2、ities,TPM概略 TPM Overview,何谓 TPM What is TPM,全员生产保养是这样一个系统 Total Productive Maintenance is a system that 涉及工场 / 维修人员 Involves both shopfloor associates and maintenance associates 支持精益西格玛流程 Supports the LeanSigma Process 保持设备最佳状态 Keeps equipment in optimal condition,为何要实施 TPM Why Implement TPM?,忽视设备基本
3、状况 Basic Equipment conditions neglected 操作维修技能欠佳 Insufficient operating and maintenance skills 设备设计固有不足 Inherent weakness in equipment design 设备恶化无人监督 Overlooked deterioration 没有遵守使用要求 Usage conditions not observed,宏观愿景 Macro Vision,TPM 世界性的公司 World Wide Company,工人自主保养 Operator Autonomous Maintenanc
4、e,预防保养 Preventive Maintenance,经理支持功能 Manager Support Function,工程设备 设计改善 Eng. Equip. Design Improvement,品质改善 Quality Improvement,全员生产保养 T P M,高级管理层领导 S M L,生产准备 2P,西格玛改善 Sigma Kaizen,TPM目标 TPM Goals,零故障 Zero Breakdowns 零缺陷 Zero Defects 零事故 Zero Accidents 全员参与 Total employee involvement 提高机器效率, 满足节拍速度
5、 Achieve Takt Rate at the highest machine effectiveness,TPM与精益西格玛流程 TPM and LeanSigma Process,精益西格玛 LeanSigma Process,及时 生产 Just in Time,自働化 Jidoka,畅顺生产 Production Smoothing,机器可靠 Machine Reliability 机器高效 Machine Effectiveness 联动操作 Linked Operations 人力利用 Labor Utilization,制程能力 Process Capability 最佳机况
6、 Optimal machine conditions 制程重复 Process Repeatability 防错装置 Mistake Proofing,实现流畅生产, 必须实行TPM TPM is essential when flow production is achieved,TPM与传统保养 TPM vs. Traditional Maintenance,每班8小时 8 hr shift,有效时间 = 7小时40分 Effectiveness = 7 hrs 40min,工人开会: 10分钟 Operator Meeting,10 min,10 min,设备清洁与润滑: 10分钟 E
7、quipment cleaning & Lubrication,传统生产班次 Traditional Operating Shift :,实行TPM的班次 TPM Shift :,本班开始 Shift Start,品质问题 Quality,暂停 Minor Stoppages,故障停机 Breakdown,调整 Adjustment,本班结束 Shift End,每班8小时 8 hr shift,有效时间 = 6小时 Effectiveness = 6 hrs,量度指标 Metrics,整体设备效率 Overall Equipment Effectiveness (OEE) 可用效率 Avai
8、lability 性能效率 Performance 品质效率 Quality,保养效率 Maintenance Effectiveness 平均故障时间间隔 MTTF (Mean time to failure) 平均无故障时间 MTBF (Mean time between failure) 平均维修时间 MTTR (Mean time to repair),TPM的目的：The Aim of TPM :,改善设备运行状况 To improve the equipment operating condition 维持设备最佳性能与可靠性 To sustain equipment at an
9、optimal level of performance & reliability 延长设备使用寿命 To lengthen the life expectancy of equipment,TPM流程 TPM Process,TPM五大支柱 The 5 Pillars of TPM,自主保养 Autonomous Maintenance,计划保养 Planning Maintenance,预防工程 Preventive Engineering,品质 Quality,教育与行动 Education & Practice,实施TPM十步骤 TPM Implementation -10 Step
10、s,1. 测量工作单元上所有自动设备之OEE Measure OEE for all automatic equipment in cells. 2. 测量各工作单元的节拍时间 Measure Takt rate performance for each area. 3. 将单元节拍时间与设备OEE进行比较 Correlate cell takt rate performance to equipment OEE. 4. 选择特定机器作为改善重点 Select specific machine for kaizen focus. 5. 根据OEE六大损失制定改善目标 Establish imp
11、rovement goal related to the six major losses of OEE. 6. 选定设备改善专职队员 Select permanent equipment improvement team members. 7. 发动工人进行自主保养及计划保养活动 Initiate operator autonomous maintenance and planned maintenance programs. 8. 继续更新检查单, 培训工人, 保证机器最佳状况 Continue to update check lists, train operators, and pur
12、sue optimal machine conditions. 9. 为选定设备设立TPM活动之目视表现板 Establish visual performance boards for TPM activities on selected equipment. 10. 每月将改善目标与实际结果进行比较。评价是否需要进行更多改善活动, 制定更高的目标, 或需要更换专职队员 Check results to improvement goals monthly. Evaluate need for additional kaizen activity, setting more aggressiv
13、e goals, or modifying permanent team members.,自主保养 Autonomous Maintenance,自主保养 Autonomous Maintenance,工人要学习 A system where equipment operators learn to : 进行每日检查 Perform daily checks 按需润滑设备 Lubricate equipment as needed 更换简单零件 Replace simple components 进行机器小修 Perform minor repairs on machines 帮助解决问题
14、Assist in problem solving,工人是机器发生异常的早期预警系统 Operators become the early warning system for machine abnormalities,自主保养五步法 5 Steps to Autonomous Maintenance,1. 进行基本清洁活动 Perform basic cleaning 2. 根除肮脏污染源头 Eliminate sources of dirt and contamination 3. 建立清洁润滑标准 Establish cleaning and lubrication standards
15、 4. 教会设备基本检查, 进行自主设备检查 Teach general inspection of equipment and Perform autonomous equipment inspection 5. 培养整齐有序习惯 Instill orderliness and organization,工人作用 Roles of Operators,预防污染 Prevent deterioration : 维持基本条件 Maintaining basic conditions 正确操作设备 Operating equipment correctly 判断污染 Measure deterio
16、ration : 进行检查 Inspecting 制定标准, 坚持执行 Developing and adhering to standards,纠正污染 Correct deterioration : 报告问题 Reporting problems 协助维修 Assisting in repairs 进行微调 (按本地合约) Making minor adjustments (per local contract) 加入团队 Participate in teams : 工作中心团队 Work center teams 解决问题团队 Problem-solving teams,维修人员作用 Roles of Maintenance Personnel,设备保养 Maintain Equipment 检验 (拆卸) Inspect (disassembly) 计划保养 Planned overhauls 预防保养 Preventive maintenance 教导工人学会特定保养工作 Teach selecte
