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1、全面生产维护 (TPM)全面生产维护 (TPM)TPMTPM 团队组织设备综合利用率OEE TPM 活动步骤RD011202Total Productive Maintenance (TPM)Total Productive Maintenance (TPM)TPMTPM Team OrganizationOverall Equipment Effectiveness TPM PhasesRD011202Total Productive Maintenance (TPM)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
2、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
3、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 1-12-02Total Productive Maintenance (TPM)Lean Six Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerF
4、inalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop Data Collection PlanConduct Measurement System AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on
5、 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 MetricsTran
6、sition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureDefineProject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-
7、Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp & CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE
8、Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-02Total Productive Maintenance (TPM)课程目的学习一种方法以便: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）;消除导致设备故障的因素;使设备的养护清洁更易达成;用预测性保养作为一种检测工具;实施维护审
9、查Total Productive Maintenance (TPM)Learning ObjectivesLearn a method to:Integrate operational productivity factors applicable in process industries in a single comprehensive measurementEliminate factors contributing to equipment failureImprove accessibility for cleaning and maintaining equipmentUse
10、predictive maintenance as a diagnostic toolImplement maintenance auditsTotal Productive Maintenance (TPM)个人学习意义流程作业和保养最优化一种替代传统的在故障发生时检测并修复的方法;一种源头监控和校正的先发系统;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)Whats in It for Me?Optimized process operations and maintenanceA method to repl
11、ace the traditional approach of detecting and correcting faulty conditions as they occurA proactive system which monitors and corrects causesAn operations strategy based on understanding the cause and effect system affecting the major contributors to process performanceTotal Productive Maintenance (
12、TPM)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)Total Productive Maintenance (TPM)TPM DefinitionA common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and
13、 Maintenance.Total Productive Maintenance (TPM)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 Maintenance (TPM)TPMAchieve zero equipment breakdowns and zero defects through preventionEstablish prevention byMaintaining normal conditionsEarly detection of abnormalitiesQuick resp
14、onseTotal Productive Maintenance (TPM)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;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)Traditional Approach“Re-Active Maintenance”Maintenance “WE FIX”Perform all maintenance activitiesPerform “Fire Fighting” maintenance when a machine breakdown occursOrder and administer all tooling, supplies, etc.Perform Preventive MaintenanceManufacturing “WE OPERATE”Generally does not perform any maintenance activ
