精益生产之全面生产维护TPM中英文版课件

MeasureMeasureAnalyzeAnalyzeControlControlImproveImproveLean Six SigmaLean Six Sigma全面生产维护(TPM)uTPMuTPM 团队组织u设备综合利用率OEE uTPM 活动步骤RD011202MeasureMeasureAnalyzeAnalyzeControlControlImproveImproveLean Six SigmaLean Six SigmaTotal Productive Maintenance(TPM)uTPMuTPM Team OrganizationuOverall Equipment Effectiveness uTPM PhasesRD011202ControlControl精益6 过程改善流程分析分析分析分析控制控制控制控制改进改进改进改进定义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 别转化机会测量测量测量测量定义定义定义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RACIQuad 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&RCp&Cpk供应链加速器分析多变动图i盒状图交互作用图回归分析ANOVAC&E 矩阵图FMEA脑力风暴拉系统减少设置TPM流程图标杆管理亲和图DOE 假设检验力场分析图树状图甘特图查检表运行图柱状图散布图控制图柏拉图互动回顾愚巧法Revised 1-12-023Total Productive Maintenance(TPM)ControlControlLean Six Sigma Improvement Process Road MapAnalyzeAnalyzeControlControlImproveImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureMeasureDefineDefineProject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp&CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-024Total Productive Maintenance(TPM)ControlControl课程目的u学习一种方法以便:n将作业流程中的起作用的所有生产要素整合为一个单一综合的衡量值（OEE）;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具;n实施维护审查5Total Productive Maintenance(TPM)ControlControlLearning ObjectivesuLearn a method to:nIntegrate operational productivity factors applicable in process industries in a single comprehensive measurementnEliminate factors contributing to equipment failurenImprove accessibility for cleaning and maintaining equipmentnUse predictive maintenance as a diagnostic toolnImplement maintenance audits6Total Productive Maintenance(TPM)ControlControl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;7Total Productive Maintenance(TPM)ControlControlWhats in It for Me?uOptimized process operations and maintenanceuA method to replace the traditional approach of detecting and correcting faulty conditions as they occuruA proactive system which monitors and corrects causesuAn operations strategy based on understanding the cause and effect system affecting the major contributors to process performance8Total Productive Maintenance(TPM)ControlControl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。9Total Productive Maintenance(TPM)ControlControlTotal Productive Maintenance(TPM)TPM DefinitionuA common sense approach to monitor operations,maintain equipment,eliminate unscheduled downtime,and improve the level of cooperation between Operations and Maintenance.10Total Productive Maintenance(TPM)ControlControlTPMu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11Total Productive Maintenance(TPM)ControlControlTPMuAchieve zero equipment breakdowns and zero defects through preventionuEstablish prevention bynMaintaining normal conditionsnEarly detection of abnormalitiesnQuick response12Total Productive Maintenance(TPM)ControlControl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13Total Productive Maintenance(TPM)ControlControlTraditional Approach“Re-Active Maintenance”Maintenance“WE FIX”nPerform all maintenance activitiesnPerform“Fire Fighting”maintenance when a machine breakdown occursnOrder and administer all tooling,supplies,etc.nPerform Preventive MaintenanceManufacturing“WE OPERATE”nGenerally does not perform any maintenance activitiesnContacts maintenance when a machine breakdown occursnInactive during maintenance activitiesn“Run it till it breaks”14Total Productive Maintenance(TPM)ControlControl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