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1、Time Based ManagementP SKBP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.全员生产保养全员生产保养全员生产保养全员生产保养Total
2、Productive MaintenanceTotal Productive Maintenance8 8 - - 2 2 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB目录目录 Table of ContentsTPM概略概略 TPM OverviewTPM目的目的 The Aim of TPMTPM流程流程 TPM Process自主保养自主保养 Autonomous Maintenance计划保养计划保养
3、Planned Maintenance预防工程预防工程 Preventive Engineering教育与行动教育与行动 Education & Practice保证质量保证质量 Insured QualityTPM改善活动改善活动 TPM Kaizen ActivitiesTPM活动进阶活动进阶 Advanced TPM ActivitiesTime Based ManagementP SKBP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights
4、 Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.TPMTPM概略概略概略概略TPM OverviewTPM Overview8 8 - - 4 4 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P
5、SKBP SKB何谓何谓 TPM What is TPM全员生产保养全员生产保养全员生产保养全员生产保养是这样一个系统是这样一个系统T Total P Productive M Maintenance is a system that 涉及工场涉及工场 / 维修人员维修人员Involves both shopfloor associates and maintenance associates 支持支持精益西格玛流程精益西格玛流程Supports the LeanSigma Process 保持设备最佳状态保持设备最佳状态Keeps equipment in optimal condition
6、 8 8 - - 5 5 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB为何要实施为何要实施 TPM Why Implement TPM?忽视设备基本状况忽视设备基本状况Basic Equipment conditions neglected 操作维修技能欠佳操作维修技能欠佳Insufficient operating and maintenance skills 设备设计固有不足设备设计固有不足Inherent
7、 weakness in equipment design 设备恶化无人监督设备恶化无人监督Overlooked deterioration 没有遵守使用要求没有遵守使用要求Usage conditions not observed 8 8 - - 6 6 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB宏观愿景宏观愿景 Macro VisionTPM世界性的公司世界性的公司World Wide Company工人
8、自主保养工人自主保养OperatorAutonomousMaintenance预防保养预防保养Preventive Maintenance经理支持功能经理支持功能ManagerSupportFunction工程设备工程设备设计改善设计改善Eng. Equip.DesignImprovement品质改善品质改善QualityImprovement全员生产保养全员生产保养T P M高级管理层高级管理层领导领导 S M L生产准备生产准备2P西格玛改善西格玛改善Sigma Kaizen8 8 - - 7 7 2008 TBM Consulting Group, Inc. All Rights Res
9、erved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKBTPM目标目标 TPM Goals零故障零故障 Zero Breakdowns 零缺陷零缺陷 Zero Defects 零事故零事故 Zero Accidents 全员参与全员参与 Total employee involvement 提高机器效率提高机器效率, 满足节拍满足节拍速度速度Achieve Takt Rate at the highest machine effectiveness 8 8 - - 8 8 2008 TBM Consulting
10、Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKBTPMTPM与精益西格玛流程与精益西格玛流程与精益西格玛流程与精益西格玛流程 TPM and TPM and LeanSigma ProcessLeanSigma Process精益西格玛精益西格玛精益西格玛精益西格玛LeanLeanSigma ProcessSigma Process及时及时及时及时生产生产生产生产JustJustin inTimeTime自働化自働化自働化自働化JidokaJidoka畅
11、顺生产畅顺生产畅顺生产畅顺生产 Production SmoothingProduction Smoothing机器可靠机器可靠Machine Reliability机器高效机器高效Machine Effectiveness联动操作联动操作Linked Operations人力利用人力利用Labor Utilization制程能力制程能力Process Capability最佳机况最佳机况Optimal machine conditions制程重复制程重复Process Repeatability防错装置防错装置Mistake Proofing实现流畅生产实现流畅生产, 必须实行必须实行TPM
12、TPM is essential when flow production is achieved8 8 - - 9 9 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKBTPM与传统保养与传统保养 TPM vs. Traditional Maintenance每班每班8小时小时 8 hr shift有效时间有效时间 = 7小时小时40分分 Effectiveness = 7 hrs 40min工人开会工人开会: 1
13、0分钟分钟Operator Meeting10 min10 min设备清洁与润滑设备清洁与润滑: 10分钟分钟Equipment cleaning & Lubrication 传统传统生产生产班次班次 Traditional Operating Shift :实行实行实行实行TPMTPM的班次的班次的班次的班次 TPM ShiftTPM Shift : :本班开始本班开始 Shift Start品质问题品质问题 Quality暂停暂停 Minor Stoppages故障停机故障停机 Breakdown调整调整 Adjustment本班结束本班结束 Shift End每班每班8小时小时 8 hr
14、 shift有效时间有效时间 = 6小时小时 Effectiveness = 6 hrs8 8 - - 1010 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB量度指标量度指标 Metrics整体设备效率整体设备效率 Overall Equipment Effectiveness (OEE)可用效率可用效率 Availability性能效率性能效率 Performance品质效率品质效率 Quality保养效率保
15、养效率 Maintenance Effectiveness平均故障时间间隔平均故障时间间隔 MTTF (Mean time to failure)平均无故障时间平均无故障时间 MTBF (Mean time between failure)平均维修时间平均维修时间 MTTR (Mean time to repair)Time Based ManagementP SKBP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.Lean
16、Sigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.TPMTPM的目的：的目的：的目的：的目的：The Aim of TPMThe Aim of TPM : :改善设备运行状况改善设备运行状况To improve the equipment operating condition 维持设备最佳性能与可靠性维持设备最佳性能与可靠性To sustain equipment at an optim
17、al level of performance & reliability 延长设备使用寿命延长设备使用寿命To lengthen the life expectancy of equipment Time Based ManagementP SKBP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consult
18、ing Group logo are registered trademarks of TBM Consulting Group Inc.TPMTPM流程流程流程流程TPM ProcessTPM Process8 8 - - 1313 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKBTPM五大支柱五大支柱 The 5 Pillars of TPM自主保养自主保养 Autonomous Maintenance计划保养
19、计划保养PlanningMaintenance预防工程预防工程PreventiveEngineering品质品质Quality 教育与行动教育与行动Education& Practice8 8 - - 1414 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB实施实施TPM十步骤十步骤 TPM Implementation -10 Steps1.测量工作单元上所有自动设备之测量工作单元上所有自动设备之OEEMeas
20、ure OEE for all automatic equipment in cells. 2.测量各工作单元的节拍时间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将单元节拍时间与设备OEE进行比较进行比较Correlate cell takt rate performance to equipment OEE. 4.选择特定机器作为改善重点选择特定机器作为改善重点Select specific machine for kaizen focus. 5.根据根据OEE六大损失制定改善目标六大损失制定改善
21、目标Establish improvement goal related to the six major losses of OEE.6.选定设备改善专职队员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.继续更新检查单继续更新检查单, 培训工人培训工人, 保证机器最佳状况保证机器最佳状况Con
22、tinue to update check lists, train operators, and pursue optimal machine conditions. 9.为选定设备设立为选定设备设立TPM活动之目视表现板活动之目视表现板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, 制定更制定更高的目标高的目标, 或需要更换专职队员或需要更换专职队员C
23、heck results to improvement goals monthly. Evaluate need for additional kaizen activity, setting more aggressive goals, or modifying permanent team members. Time Based ManagementP SKBP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSi
24、gma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.自主保养自主保养自主保养自主保养Autonomous MaintenanceAutonomous Maintenance8 8 - - 1616 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Rese
25、rved.P SKBP SKB自主保养自主保养 Autonomous Maintenance工人要学习工人要学习 A system where equipment operators learn to :进行每日检查进行每日检查 Perform daily checks按需润滑设备按需润滑设备 Lubricate equipment as needed更换简单零件更换简单零件 Replace simple components进行机器小修进行机器小修 Perform minor repairs on machines帮助解决问题帮助解决问题 Assist in problem solving工
26、人是机器发生异常的早期预警系统工人是机器发生异常的早期预警系统Operators become the early warning systemfor machine abnormalities8 8 - - 1717 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB自主保养五步法自主保养五步法 5 Steps to Autonomous Maintenance1.进行基本清洁活动进行基本清洁活动Perform b
27、asic cleaning 2.根除肮脏污染源头根除肮脏污染源头Eliminate sources of dirt and contamination 3.建立清洁润滑标准建立清洁润滑标准Establish cleaning and lubrication standards 4.教会设备基本检查教会设备基本检查, 进行自主设备检查进行自主设备检查Teach general inspection of equipment and Perform autonomous equipment inspection 5.培养整齐有序习惯培养整齐有序习惯Instill orderliness and o
28、rganization 8 8 - - 1818 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB工人作用工人作用 Roles of Operators预防污染预防污染 Prevent deterioration :维持基本条件维持基本条件Maintaining basic conditions 正确操作设备正确操作设备Operating equipment correctly 判断污染判断污染Measure de
29、terioration :进行检查进行检查Inspecting 制定标准制定标准, 坚持执行坚持执行Developing and adhering to standards 纠正污染纠正污染Correct deterioration :报告问题报告问题Reporting problems 协助维修协助维修Assisting in repairs 进行微调进行微调 (按本地合约按本地合约)Making minor adjustments (per local contract) 加入团队加入团队Participate in teams :工作中心团队工作中心团队Work center teams
30、 解决问题团队解决问题团队Problem-solving teams 8 8 - - 1919 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB维修人员作用维修人员作用 Roles of Maintenance Personnel设备保养设备保养Maintain Equipment 检验检验 (拆卸拆卸)Inspect (disassembly) 计划保养计划保养Planned overhauls 预防保养预防保养
31、Preventive maintenance 教导工人学会特定保养工作教导工人学会特定保养工作Teach selected maintenance tasks to operators 设备改善设备改善Improve Equipment 支持可靠性及可维修性改善支持可靠性及可维修性改善Support R&M improvement 实施预测技术实施预测技术Implement predictive technologies 纠正设计不足纠正设计不足Correct design weaknesses 搞好供方合作搞好供方合作Partner with vendors 8 8 - - 2020 200
32、8 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB设备检查表设备检查表 Equipment Inspection Checklist初步清洁初步清洁 Initial Cleaning螺母、螺栓等有无松动、摇摆、遗失螺母、螺栓等有无松动、摇摆、遗失?Any nuts, bolts, etc. loose, wobbly or missing? 活动零件、夹具安装有无窜动活动零件、夹具安装有无窜动?Any play in mo
33、ving parts or fixture mounting section? 机器内部有无多余零件机器内部有无多余零件?Any unnecessary items located on the body of the machine? 润滑系统润滑系统 Lubrication润滑油是否到达滑动部件润滑油是否到达滑动部件? Does oil reach sliding parts? 润脂嘴、机油盖等是否损坏、遗失润脂嘴、机油盖等是否损坏、遗失?Any damaged or missing grease nipples, oil caps, etc.? 供油装置、管路、接头有无漏油供油装置、管路
34、、接头有无漏油?Any oil or grease leaks from supply devices, pipes, fittings? 加油工人有无内外清洁加油工人有无内外清洁? Are oilers clean inside or out? 油标是否容易看见油标是否容易看见? Is the oil level easily visible? 8 8 - - 2121 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP
35、SKB设备检查表设备检查表 Equipment Inspection Checklist液压系统液压系统 Hydraulics油箱装够油了吗油箱装够油了吗? Is the oil tank filled to the specified level? 油泵发出异常噪音吗油泵发出异常噪音吗? Is the pump emitting any abnormal noises? 卸荷阀、减压阀、节流阀防松螺母上紧了吗卸荷阀、减压阀、节流阀防松螺母上紧了吗?Are locknuts tight on relief, reducing and throttle valves? 卸荷阀、控制装置运作正常吗
36、卸荷阀、控制装置运作正常吗?Are relief valves and controls operating correctly? 高压管路连接变形或磨损了吗高压管路连接变形或磨损了吗?Any strain or wear in high pressure hose connections? 电器系统电器系统 Electrical行程开关杠杆能够完全接触吗行程开关杠杆能够完全接触吗? Do limit switch bars strike fully? 信号灯、指示灯遗失或烧坏了吗信号灯、指示灯遗失或烧坏了吗?Any missing or burned out pilot or indicat
37、or lights? 配电盘、电器箱有无线路图配电盘、电器箱有无线路图?Are there wiring diagrams in the control panels or electrical boxes? 有无多余的、损坏的、压坏的电线或软管有无多余的、损坏的、压坏的电线或软管?Any unnecessary, damaged or dented wires or flexible tubing? 8 8 - - 2222 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc.
38、 All Rights Reserved.P SKBP SKB设备检查表设备检查表 Equipment Inspection Checklist传动系统传动系统 Power Transfer DevicesV型皮带碰到带轮槽底了吗型皮带碰到带轮槽底了吗?Do V-belts hit the bottom of pulley grooves? 皮带有无损坏、爆裂、破裂皮带有无损坏、爆裂、破裂?Any damage, cracking or splitting of the belts? 滚柱链条的销轴与轴承之间有无足够润滑油滚柱链条的销轴与轴承之间有无足够润滑油?Is there suffici
39、ent lubrication between pins and bushings of roller chains? 转轴有无过热、振动、噪音转轴有无过热、振动、噪音?Any shaft overheating, vibration or noise? 联接系统有无锁键、夹紧螺栓松动造成的窜动联接系统有无锁键、夹紧螺栓松动造成的窜动?Any play due to loose keys or clamping bolts on couplings? 齿轮机构有无过量的躁音、发热、振动齿轮机构有无过量的躁音、发热、振动?Any excess noise, heat or vibration i
40、n gear mechanisms? 8 8 - - 2323 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB设备检查表设备检查表 Equipment Inspection Checklist螺母螺栓螺母螺栓 Nuts and Bolts登记记号允许松紧度检查吗登记记号允许松紧度检查吗?Do registration marks permit tightness checks? 螺母螺栓型号及尺寸正确吗螺母螺栓型
41、号及尺寸正确吗?Are nuts and bolts of the suitable types or sizes used? 垫片尺寸正确垫片尺寸正确, 且类型相配吗且类型相配吗?Are washers of proper size, and are they consistently used? 螺栓有从螺母凸出螺栓有从螺母凸出23圈螺纹吗圈螺纹吗?Do bolts protrude 2 3 threads from the nuts? 气动系统气动系统 Pneumatics截止阀及球阀漏气吗截止阀及球阀漏气吗? Any stop valve, ball valve leaks? 有坏了或
42、多余的手把吗有坏了或多余的手把吗? Any broken or unnecessary handles? 已关闭的阀仍有气流吗已关闭的阀仍有气流吗? Does any air flow through closed valves? 有任何不必要的装置或喉管吗有任何不必要的装置或喉管吗?Are any unnecessary devices, hoses or pipes present? 所有喉管都整齐及易于识别吗所有喉管都整齐及易于识别吗?Are pipes and hoses orderly and readily identifiable? 压力表指示的都是正确设定的压力吗压力表指示的都
43、是正确设定的压力吗?Do pressure gauges clearly indicate the correct set pressure? 8 8 - - 2424 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB进行基本清洁进行基本清洁 Perform Basic Cleaning做好清洁检查做好清洁检查 Clean to inspect暴露隐藏不足暴露隐藏不足 Expose hidden defects找出
44、脏污源头找出脏污源头 Determine source of contamination识别难于清洁之处识别难于清洁之处 Identify hard to reach areas准备蓝色标签工作准备蓝色标签工作 Prepare for blue tag exercise8 8 - - 2525 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB消灭脏污源头消灭脏污源头 Eliminate Sources Of Dir
45、t & Contamination脏污原因脏污原因 Causes of Contamination:发生液体泄漏发生液体泄漏 Fluid leaks 碎片容器很差碎片容器很差 Poor chip containment 工作不佳工作不佳 Poor 5S practices 工作区有溅洒工作区有溅洒 Work area spills 过滤性能不好过滤性能不好 Poor filtration 没有清洁标准没有清洁标准 No cleaning standards 无工作自豪感无工作自豪感 Poor work pride 环境问题恶劣环境问题恶劣 Environment 8 8 - - 2626 20
46、08 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB建立清洁与润滑标准建立清洁与润滑标准Establish Cleaning & Lubrication Standards 从工人开始进行基本的清洁、检查及润滑活动从工人开始进行基本的清洁、检查及润滑活动Begin basic operator cleaning, inspecting and lubricating activities 制定临时标准制定临时标准 Esta
47、blish provisional standards 进行重点训示进行重点训示 Create one point lesson 确定活动频次确定活动频次 Establish frequency of activities 月检、周检、日检清单月检、周检、日检清单Monthly, weekly and daily check list 制做检查表制做检查表 Develop check list 8 8 - - 2727 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All
48、 Rights Reserved.P SKBP SKB重点训示重点训示 One-Point Lesson1.0 目的目的/范围范围: 根据根据3600路线检查单脂具体检查步骤制定详细的工作指示路线检查单脂具体检查步骤制定详细的工作指示2.0 责任责任: 工人工人3.0 安全安全: 标准的工人保护设备标准的工人保护设备: 防护眼镜防护眼镜, 听觉保护用具听觉保护用具, 手套手套, 钢头鞋钢头鞋4.0 工作指示工作指示第第1步步: 本工作指示用于与本工作指示用于与3600路线检路线检查单有关的工作查单有关的工作第第2步步: 本工作指示用于本工作指示用于3600吨冲压机吨冲压机周围的检查工作周围的检
49、查工作35第第3步步: 检查模具加热炉温度及设定值。检查模具加热炉温度及设定值。绝对最低设定值应为绝对最低设定值应为800度度8 8 - - 2828 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB进行自主保养检查进行自主保养检查Perform Autonomous Maintenance Inspection制定详细的培训计划制定详细的培训计划Develop in depth training program
50、对工人就以下内容进行培训：对工人就以下内容进行培训：Train operators in: 润滑作用润滑作用/粘性分析粘性分析 Lubrication/ Viscosity Analysis 气动系统气动系统 Pneumatics 液压系统液压系统 Hydraulic 电气系统电气系统 Electrical systems 驱动系统驱动系统 Drive systems 修改目前的重点训示修改目前的重点训示, 加入检验检查工作加入检验检查工作Revise existing one-point lessons to include inspection checks 8 8 - - 2929 20
51、08 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB灌输工场整洁条理思想灌输工场整洁条理思想Instill Orderliness & Organization 工场管理与控制工场管理与控制 Workplace management & control 扩展团队活动扩展团队活动, 做好设备以外的整洁工作做好设备以外的整洁工作Expand team activities beyond equipment to other a
52、spects of the process 搞好工场整洁搞好工场整洁, 实行目视控制，发现改善机会实行目视控制，发现改善机会 (第第4、5个个S)Expose opportunities for improved organization, orderliness and visual control (4th & 5th S) 进行进行5S评审评审 Perform 5S audits 8 8 - - 3030 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rig
53、hts Reserved.P SKBP SKB整洁与条理整洁与条理 Organization & Orderliness8 8 - - 3131 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB目视控制目视控制 Visual Controls写出已做的活动写出已做的活动, 展示取得的进步展示取得的进步Describes activities undertaken and shows progress 对比制定的标准
54、对比制定的标准, 量化取得的改善量化取得的改善 故障停机、维修呼故障停机、维修呼叫、停线时间等叫、停线时间等Quantifies the improvements made against agreed metrics. e.g. (Breakdowns, defects, maintenance call-outs, line down-time, etc.) 细化实际的改善细化实际的改善 Details the actual improvements made 记录待研究项目记录待研究项目 Records issues to be reviewed: 没有答复的问题没有答复的问题 Unan
55、swered questions 需要支援的问题需要支援的问题 Complex issues support required 8 8 - - 3232 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB问题公报问题公报ProblemNewspaper问题公报问题公报ProblemNewspaper生产保养完成率生产保养完成率PM Completion Ratio保养小组目视控制保养小组目视控制Maintenance
56、 Group Visual Control8 8 - - 3333 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB活动布告板活动布告板 Activity Board自主保养自主保养自主保养自主保养Time Based ManagementP SKBP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group
57、, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.全员生产保养活动全员生产保养活动全员生产保养活动全员生产保养活动TPM ActivitiesTPM Activities8 8 - - 3535 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consu
58、lting Group, Inc. All Rights Reserved.P SKBP SKB进行进行TPM基础基础知识培训，知识培训，评审准备工评审准备工作作Train in TPM fundamentals & Review Pre-work 实施蓝色标实施蓝色标签方法签方法Conduct Blue Tag Exercise 异常情况排异常情况排序序Rank abnormalities 异常情况维异常情况维修修Repair abnormalities设备设备OEM手手册评审册评审Review equipment OEM manuals 确定工人自确定工人自主保养路线主保养路线, 制定检查
59、表制定检查表Create Op. AM route & Check sheet 定义定义 / 实施标实施标准化工作准化工作Define & Implement Std Work 实现保养反馈实现保养反馈循环循环Implement feedback loop to maintenance 进行进行OEE表现表现公告公告Implement OEE performance board 向管理层展向管理层展示结果示结果Presentation to Mgrs. 初步活动初步活动初步活动初步活动 自主保养自主保养自主保养自主保养Initial Events Autonomous MaintenanceI
60、nitial Events Autonomous MaintenanceTPM的活动的活动 TPM Activities8 8 - - 3636 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB改善前活动改善前活动 (专职队员专职队员) Pre-Kaizen Activity (Permanent Team)收集改善活动一个月前的停机数据收集改善活动一个月前的停机数据Collect downtime data fo
61、r one month prior to event 进行设备基本清洁活动进行设备基本清洁活动Conduct initial cleaning of equipment 收集设备规格、收集设备规格、OEM手册、机器手册、机器BOM及图纸及图纸Gather machine specifications, OEM manuals, machine BOM, blueprints 8 8 - - 3737 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Re
62、served.P SKBP SKB改善活动改善活动 (改善团队成员改善团队成员) Kaizen Activity (Kaizen Team)进行两小时的观察进行两小时的观察 Conduct two-hour observation 清洁脏污源头清洁脏污源头, 贴上蓝色标签贴上蓝色标签Clean and Blue Tag sources of dirt and contamination 集思广益集思广益 按实施难易程度排序按实施难易程度排序Brainstorm ideas Prioritize according to implementation ease 实施解决方案实施解决方案, 消除脏
63、污源头消除脏污源头Implement solutions to eliminate sources of contamination 设计工人自主保养路线、检查表及重点训示设计工人自主保养路线、检查表及重点训示, 实现保养标准实现保养标准化化Standardize and develop Operator Autonomous Maintenance Routes, Check Sheets and One-point lesson 实行实行OEE表现公告制度表现公告制度 Implement OEE performance board 实施设备保养反馈循环实施设备保养反馈循环Implement
64、 equipment maintenance feedback loop 8 8 - - 3838 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB清洁检查清洁检查 Clean To Inspect改善前改善前 Before改善后改善后 After8 8 - - 3939 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting
65、 Group, Inc. All Rights Reserved.P SKBP SKB蓝色标签流程蓝色标签流程 Blue Tag Process识别脏污及异常源头识别脏污及异常源头 Identify sources of contamination and malfunctions 每个源头贴上蓝色标签每个源头贴上蓝色标签 Write a blue tag for each identified item 在机器上靠近源头处挂上蓝色标签在机器上靠近源头处挂上蓝色标签Attach blue tag to machine at location of specific item 在总表上记录蓝色标
66、签资料在总表上记录蓝色标签资料Document Tag Information on Summary Chart 与保养人员评审蓝色标签与保养人员评审蓝色标签, 按影响程度及修理难易程度排序按影响程度及修理难易程度排序Review tags with maintenance personnel as a team & rank according to impact & difficulty of repair 改善活动期间没有解决的异常问题改善活动期间没有解决的异常问题, 保养人员要做好行动计划保养人员要做好行动计划, 列明负列明负责人及时间要求责人及时间要求Maintenance comp
67、letes Who and When information for abnormalities not repaired during kaizen event and creates Action Plan 改善小组更新总表状态改善小组更新总表状态 Team updates status of summary chart 在每月改善评审会议上在每月改善评审会议上, 专职队员评审总表状态专职队员评审总表状态Permanent team reviews status of summary chart at monthly kaizen review meeting 8 8 - - 4040 2
68、008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB蓝色标签蓝色标签 Blue Tag蓝色标签蓝色标签蓝色标签蓝色标签第第1部分部分第第2部分部分编号编号编号编号日期日期日期日期检查人检查人检查人检查人班次班次班次班次问题问题问题问题电气电气机械机械润滑润滑操作操作仪器仪器 / 控制机构控制机构设备设备其它其它问题简述问题简述电气电气机械机械润滑润滑操作操作设备设备仪器仪器 / 控制机构控制机构其它其它问题简述问题简述,
69、 继续见背面继续见背面问题可能影响问题可能影响可使用时间可使用时间性能性能/速度速度成品质量成品质量环境环境浪费浪费成本成本安全安全其它其它改正行动计划改正行动计划执行人执行人执行人执行人执行人执行人日期日期日期日期日期日期工作单号工作单号根本原因根本原因 / 行动行动, 更多见背面更多见背面完成日期完成日期位置位置 / 系统系统 / 设备设备 / 零件代号零件代号8 8 - - 4141 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserve
70、d.P SKBP SKB不足之处不足之处, 贴上标签贴上标签 Deficiencies Tagged 8 8 - - 4242 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB蓝色标签总表蓝色标签总表 Blue Tag Summary ChartNo.异常异常 Malfunction行动行动 Action负责人负责人Who 时间时间When OK1漏油漏油Oil leak重新设计油槽重新设计油槽, 引导及引导及接住
71、导轨油接住导轨油Need chute designed to guide and catch way lube oil 保养人员保养人员 Maint. 4/18/912油泵油泵滤网滤网上金属过上金属过滤器盖弯曲滤器盖弯曲Metal filter cover over the pump screen bent 弄直或更换弄直或更换Straighten or replace 改善队员改善队员Team 4/10/91已完成已完成Complete3盖外壳时遗失两个盖外壳时遗失两个螺丝螺丝 Two screws missing on way cover housing更换更换Replace 改善队员改善
72、队员 Team 4/18/91已完成已完成Complete4滑动门上轨道滚柱滑动门上轨道滚柱轴承遗失轴承遗失Roller bearing missing on the top track of the sliding door更换更换Replace 保养人员保养人员 Maint. 4/21/915Nachi液压泵底下漏液压泵底下漏油油Oil leak at the base of the Nachi hydraulic pump检查密封圈检查密封圈, 必要时更必要时更换换 Check gasket, replace if needed保养人员保养人员 Maint. 5/13/91机器名称机器名
73、称机器名称机器名称 Machine NameMachine Name : : Okuma LC20 B-344 Okuma LC20 B-3448 8 - - 4343 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB影响程度影响程度 /修理难易程度分级修理难易程度分级Impact / Difficulty Rating 目的目的 Used To:发现所有浪费迹象发现所有浪费迹象, 提出可能解决方案提出可能解决方案
74、Capture waste information and potential solutions 按问题清晰程度及实施难易程度按问题清晰程度及实施难易程度, 将解决方案进将解决方案进行排序行排序Rate / rank the solutions in regards to resolution of the issues and ease of implementation 8 8 - - 4444 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights R
75、eserved.P SKBP SKB标签排序矩阵图标签排序矩阵图 Tag Prioritization Matrix制程制程: 通讯技术支持呼叫流程通讯技术支持呼叫流程障碍障碍/浪费浪费根本原因根本原因解决方案解决方案/影响影响难易程度难易程度影响影响呼叫处理计算机系统培训无法快速得到参考资料无法使用Impromptu一对一培训内部培训没有工作标准太多排队无法监视和管理排队零件处理喜龙现场人员为非工作事务呼叫技术支持部门仓存资料不准确没有零件代号指引, 太多不同零件零件跟踪程序太过称长 要使用RMA跟踪方法亲访贝茨维尔 , 与技术支持人员一起工作开发快速参考模块让技术人员能使用Imprompt
76、u制定工作标准改5个队为3个队使用ACD监视器, 更好管理排队教育现场人员, 只能为工作事务呼叫技术支持部门为没有零件代号的产品设计零件代号开发零件库, 便于快速查找零件更新Fisher-Berkley零件仓存数据库为FBB零件供应商Fawn安装网络打印机为便于零件订购, 安装被喜龙及Fawn共享的订单处理数据库实现零件代号标准化, 让供应商与喜龙都使用相同的零件代号8 8 - - 4545 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserv
77、ed.P SKBP SKB影响影响 /解决的难易程度矩阵图解决的难易程度矩阵图 Impact/Difficulty MatrixImpact/Difficulty Matrix解决的难易程度解决的难易程度影影响响8 8 - - 4646 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB自主保养检查表自主保养检查表 AM Check List自主保养检查表自主保养检查表90吨冲床吨冲床日日 一一 二二 三三 四四 五
78、五 六六项目说明项目说明工人日检工人日检工人周检工人周检日日 一一 二二 三三 四四 五五 六六日期日期 备注备注: 说明潜在问题说明潜在问题员工员工 班次班次检查光帘安装正确与否, 如不正确, 则停机, 立即通知维修人员 调整冲压机, 确保在上冲程尽头而不是经过上感应器时停机检查有无漏气检查液压系统有无泄漏检查油泵有无过大躁音检查液压系统出口油温保养所有油脂加油嘴, 检查有无明显磨损进行振动分析检查液压系统的喉管及连接有无过多磨损检查行程开关有无正确安装备注：如果机器已在使用, 每个检查项目都应每周完成, 并且在完成检查后签名。8 8 - - 4747 2008 TBM Consulting
79、 Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB检查路线检查路线 Inspection Route1650检查路线流程图检查路线流程图 路线路线 1 路线路线 2) 路线路线 3灰色表示楼梯或跨路线桥灰色表示楼梯或跨路线桥绿色三角形表示要按清单检查的地方绿色三角形表示要按清单检查的地方1650吨冲压机吨冲压机钢胚炉钢胚炉8 8 - - 4848 2008 TBM Consulting Group, Inc. All Rights Reserved. 2
80、008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB重点训示重点训示 One-Point Lesson1.0 目的目的/范围范围: 根据根据3600路线检查单具体检查步骤制定详细的工作指示路线检查单具体检查步骤制定详细的工作指示2.0 责任责任: 工人工人3.0 安全安全: 标准的工人保护设备标准的工人保护设备: 防护眼镜防护眼镜, 听觉保护用具听觉保护用具, 手套手套, 钢头鞋钢头鞋4.0 工作指示工作指示第第1步步: 本工作指示用于与本工作指示用于与3600路线检路线检查单有关的工作查单有关的工作第第2步步: 本工作指示
81、用于本工作指示用于3600吨冲压机吨冲压机周围的检查工作周围的检查工作35第第3步步: 检查模具加热炉温度及设定值。检查模具加热炉温度及设定值。绝对最低设定值应为绝对最低设定值应为800度度8 8 - - 4949 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB重点训示重点训示 One-Point Lesson目视工具目视工具 Visual Aids检查设备时不能推测检查设备时不能推测Eliminate “gue
82、sswork” in determining equipment checks. 每台设备都要有重点训示每台设备都要有重点训示Created “point one” lessons for each equipment check. 设备加上绿色三角形设备加上绿色三角形Added Green Triangles to Equipment 绿色三角形表示要按绿色三角形表示要按清单检查的地方清单检查的地方Green triangles represent areas that are to be checked in accordance with checklist. Press Operato
83、r步骤步骤1: 取一份空白检查表取一份空白检查表, 表表格编号格编号: 2750_RC步骤步骤2: 检查第检查第0-1点点坯坯料锯料锯确保进料辊筒转动自由确保进料辊筒转动自由步骤步骤3: 检查第检查第0-2点点坯坯料锯料锯检查锯片冷却液是否足够。检查锯片冷却液是否足够。如果不够一半如果不够一半, 则予以补充则予以补充8 8 - - 5050 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB突显检查点突显检查点 Ma
84、ke Inspection Point Visible8 8 - - 5151 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB突显检查点突显检查点 (续续) Make Inspection Points Visible (Continue)8 8 - - 5252 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Gr
85、oup, Inc. All Rights Reserved.P SKBP SKB简化检验检查简化检验检查 Make Inspection Checks Simple8 8 - - 5353 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB自主保养目视化自主保养目视化 Make AM Checks Visible目视工具目视工具 Visual Aids不要主观不要主观Remove Subjectivity 设立最大设
86、立最大/最小标准最小标准Establish MIN / MAX Levels 充当塞规作用充当塞规作用, 工人看到仪表工人看到仪表标签就知道压力范围或液体标签就知道压力范围或液体高度是否正确高度是否正确Used as a go/no-go device, the gauge labels let the operator know if the pressure ranges and fluid levels are correct. 8 8 - - 5454 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consu
87、lting Group, Inc. All Rights Reserved.P SKBP SKB活动公告板活动公告板 Activity Board自主保养自主保养自主保养自主保养8 8 - - 5555 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB根本原因基础根本原因基础训练训练Train in Root Cause fundamentals 根本原因分析根本原因分析Conduct Root Cause Ana
88、lysis 因果法因果法Cause & Effect5个为什么个为什么5 Whys 比较分析比较分析Comparative Analysis 制程能力制程能力分析分析Process Capability Study 测量系统测量系统分析分析MSA 向管理层展向管理层展示结果示结果Presentation to Mgrs. TPMTPM改善进阶改善进阶改善进阶改善进阶 解决问题的工具解决问题的工具解决问题的工具解决问题的工具Advanced TPM Kaizen Problem Solving ToolsAdvanced TPM Kaizen Problem Solving Tools跟踪运作与
89、跟踪运作与验证验证Trail Run and Validate. 修改与更新修改与更新自主保养自主保养及生产保及生产保养程序养程序Revise and Update AM & PM procedures 全员生产保养活动全员生产保养活动 TPM Activities8 8 - - 5656 2008 TBM Consulting Group, Inc. All Rights Reserved. 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBP SKB改善公报改善公报 改善活动后的活动清单改善活动后的活动清单Kaizen Newspaper Post Event Action List 项次项次Item #改善项目改善项目Kaizen Description 负责负责人人 Who时间时间 When预期结果预期结果Results (Expected) 1每每10次浇铸就清洁工模次浇铸就清洁工模Clean molds every 10 pours Matt7月月21日日 Jul. 21不良品减少不良品减少Reduced defects 2跟踪工模机构跟踪工模机构Tracking mechanism for moldsMatt7月月21日日 Jul. 21工模更干净工模更干净Cleaner molds 345678
