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1、Total Productive Maintenance OFFICE 办公室 1 Process Certification QCPC Root Cause / Corrective Action Set-Up Reduction Standard Work Mistake Proofing Market Feedback Analysis 6S Quality Clinic Activity Total Productive Maintenance ACE Office Qualifying Level TPM 2 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
2、产 准备 标准化 作业 防误措施 市场反馈 分析 6S 质量诊断 活动 全面生产性维护 ACE 办公室合格水平 3 Total 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 4 TPM Key Conc
3、ept TPM的重要概念 Left neglected. Equipment 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。 5 Total Productive Maintenance is a New Way of Working
4、全面生产性维护是一种全新的工作方式 TPM Attitude:TPM Attitude: 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.” “ “我操作，你修理。我操作，你修理。” ” “I fix, you de
5、sign.”“I fix, you design.” “ “我处理，你设计。我处理，你设计。” ” “I design, you operate.”“I design, you operate.” “ “我设计，你操作。我设计，你操作。” ” 6 Hidden 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
6、, noise, and other abnormalities. 磨损、松驰、泄露、灰尘、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 7 Component 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 contaminat
7、ion 灰尘和污染 Out of paper 缺纸 8 TPM Benefits TPM的益处 Reduced 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 wa
8、ste 减少浪费 Prevents loss of lubricant, compressed air 防止润滑油、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 9 TPM Qualifying Criteria (Business Process/Office) 3ACE Element Awareness Training for all employees oEquipment assessme
9、nt A,B & C oPM plan for 100% of category “A” equipment Whats Ahead oBRONZE TPM CRITERIA oImplement PM Plan oTrack downtime history for vital machines oProcess Management oIdentify Key Processes oIdentify Waste Elimination Opportunities Qualifying Awareness & Baseline 10 TPM 合格标准 (商业程序/办公室) 3 ACE 内容认
10、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 11 Sullair 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,
11、where unexpected motion, or an electrical or other energy source, would 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 12 WARNING 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 RESPONSIBL
12、E FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE 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 13 ACTION 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 mac
13、hine 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 Categorize 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
14、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:Category 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
15、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 Standa
16、rd 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） Category B:Category B: All other equipment/machines B B类：类：所有其它设备/机器 15 In 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 descripti
17、on/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 signature 部门经理的签名 ACTION ITEM 1: Assess All Equipment(cont.) 活动内容1：评估所有设备（待续） Department Manager Category A/B/C List A/B/C类清单 Copier Ep
18、son Printer Air conditioner Personal Comp. Personal Comp. Personal Comp. Personal Comp. B C A C C C C User Name User Name User Name User Name User Name User Name User Name Co. Name Co. Name Co. Name Co. Name Co. Name Co. Name Co. Name 43565 3217 e7654 4082 3189 2180 2345 Item物品 ID# Category类型 Title
19、Holder名义主人 Local Owner本地主人 16 Example: Office Equipment Assessment Worksheet Total Productive Maintenance, Office Equipment Assessment Worksheet Note:Evaluation for machine only. Not for networks Equipment nameDept.Equipment ID #Responsible Individual Productivity 1. How often is the equipment used
20、each day? 80% or above5 50-80%3 50% or below2 2. Is there backup/alternate equipment available? No (one of a kind)5 Yes (another dept.)3 Yes (in dept)1 3. To what extent will a failure of this equipment affect other office processes? Stops entire dept. process5 . Do other processes run through this
21、equipment? Slows other dept. processes4 Only affects this machine1 4. To what extent will a failure of this equipment affect on-time delivery? Decisively5 Somewhat2 Not Significantly1 Quality 5. How will the processes run on this equipment affect final quality of theDecisively5 finished product / se
22、rvice?Somewhat2 Not significantly1 Maintenance 6. What is the average monthly cost of repairs to this equipment?$1000 or more5 $0 - $10004 Service Contract2 7. What is the average time it takes to repair this equipment?Over 3 hours5 (Help desk response, if applicable)1 - 3 hours4 0 - 1 hour2 Safety,
23、 Environment, Housekeeping 8. Do safety enhancements need to be applied? Does the equipment need a housekeeping schedule?Both answers are “yes”5 One answer is “yes”3 “A” Machine: 32-40none are yes0 “B” Machine: 22-31Machine Category: Total Score: “C” Machine: 21 or less 17 范例: 办公室设备评估 工作表 全面生产性维护, 办
24、公室设备评估工作表 注意:仅用于机器评估。 不用于网络系统。 设备名称部门设备ID #负责人员 生产力 1. 该设备第日使用有多频繁? 80% 或以上5 50-80%3 50% 或以下2 2. 有可用的后备/替代设备吗? 没有 (其中一种)5 是的 (另一部门)3 是的 (部门内)1 3. 该设备失灵会在多大范围内影响其它设备? 阻滞了整个部门的运行5 . 其它设备的运行经过该设备吗? 减慢了其它部门的运行4 只影响到这台机器1 4. 该设备的失灵会在多大范围内影响正在进行的发送? 很明显地5 有些2 不明显1 品质 5. 该设备的运行将怎样影响产品/服务的最终品质? 很明显5 有些2 不明显
25、1 维护 6. 每月花在修理该设备上的平均费用有多少?$1000 或以上5 $0 - $10004 售后服务2 7. 平均花多少时间修理该设备?3小时以上5 (Help desk response, if applicable)1 - 3 小时4 0 - 1 小时2 安全、环境和内务管理 8. 需要增加安全性吗? 该设备需要内务管理进度表吗?答案都是“是”5 一个答案是“是” 3 “A” 类机器:32-40没有答案是“是”0 “B” 类机器:22-31 机器类型: 总分: “C” 类机器:21 或更少 18 ACTION ITEM 2: PM Plan on 100% “A” 活动内容2：针对
26、所有A类机器的PM计划 Operator PM defined for 100% of Category A machines. 为所有A类机器制定操作员PM qDetermine if there are any “A” machines in your area q确定你的工作区域是否有A 类机器 qIf there are, there must be a PM plan: q如果有，应有一个PM计划： qIn-house 内部 qOutside Contractor 外部合约人 Rev: BRevision Date: 3/ 25/98 Operator Preventive Main
27、tenance Service Card Machine: Okuma LC-30, 4 Axis, BT # 3054 Daily PM Tasks 1. Check running sight. 2. Check and fill Waylube: Vactra 2. 3. Check tramp oil and scrounger. Empty tramp oil if required. 4. Check and fill coolant: PML 9333. Weekly PM Tasks: Do Daily tasks and the following: 1. Check and
28、 fill spindle lube: DTE 24. 2. Check and fill air lubricator: DTE 24. (Shut off and drain air to fill) 3. Check motor fan filter (Change if necessary): Cat. # 030058. 4. Check and fill hydraulic tank: DTE 24. 5. Check roll filter (Change if needed): Cat. # 027793. Monthly PM Tasks: Do all tasks on t
29、his sheet. 1. Grease chuck fittings, 1 shot. 2. Grease 1 fitting, 2 shots, both turrets. 3. Clean air filter. 4. Change air filter: Cat. # 021183. 19 ACTION ITEM 2:PM Schedule on 50% A&B(contd) 活动内容2：针对50%A和B类机器的PM进度表（待续） Following is highly recommended to make Operator PM effective: 强烈推荐跟进以确保操作员PM的
30、实施： Use a “Visible at-a-glance” system (Such as a color-coded PM Status board) within the work area to indicate the actual status of “Operator PM” tasks. 使用一眼就能看见的系统 (如使用颜色代码PM状态板) 在单元中表明“操作员PM”任务的 实际状态 lMust be easy to understand lNo book or folder to read l必须容易理解 l无需翻书或文件夹 20 What is next? 下一步是什么？
31、 Complete TPM training of your work group by March 7, 2001 2001年3月7日前你的工作组应 完成TPM培训 Before the end of February, look for a groupwise announcement of a “Drivers” Meeting to discuss the necessary resources and logistics for completing qualifying TPM activities 在2月底以前，宣布召开“领导层”会议， 讨论必要的资源和后勤以帮助完成 取得合格资
32、格的TPM活动 21 We want a company that reveres people who design, build and maintain things that never break, rather than people who fix things that break. George David UTC Chairman and CEO 我们希望公司尊敬那些设计、建造并维持不会坏 的东西的人们，而不是那些修理会坏的东西的人们。 George David UTC Chairman and CEO Summary 小结 22 Total Productive Maintenance OFFICE 办公室 23