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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
3、本状况 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 Maintenan
4、ce,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
5、度 Achieve Takt Rate at the highest machine effectiveness,TPM与精益西格玛流程 TPM and LeanSigma Process,FLE,及时 生产 Just in Time,自働化 Jidoka,均衡生产 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 Optimal machine co
6、nditions 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 Equipment cleaning &
7、 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,整体设备效率 Overall Equipment Effectiveness,故障停机 Breakdowns 换模 Set-ups 调整 Adjustments,空闲 Id
8、ling 暂停 Minor Stops 速度降低 Reduced Speed,不良品 Defects 返工 Rework 启动 Start-up 合格率损失 Yield Loss,Availability =,Performance =,Quality =,Available Time Downtime Available Time,MCT X # Parts Produced Operating Time,# of Parts Produced Defects/Rework # of Parts Produced,六个主要损失 Six Major Losses,整体设备效率 % = 可用效率
9、 x 性能效率 x 品质效率 x 100% OEE (%) = Availability X Performance X Quality X 100%,Discrete Mfg.,Process Ind.,Available Time Downtime Available Time,Amount Produced Std/hr X Operating Time(hrs),Amount Defect/Rework Total Amount Produced,可用效率,性能效率,质量效率,可用时间 停机时间,可用时间,操作时间,机器周期时间 X 已生产零件数,已生产零件数 不良品数 / 返工数,已
10、生产零件数,离散式生产,流程工业,可用时间 停机时间,可用时间,标准产值/小时 x 操作时间,已生产产值,总产值 不良品 / 返工产值,已生产总产值,Equipment Utilization (availability) (when do you PLAN To run it?),Maximum Possible Production = 1440 minutes (24 hours),Planned Downtime,No 3rd shift = 420 Min. Lunch (2 shifts) = 60 Min. Dept. Meetings = 20 Min. Planned Dow
11、ntime = 500 Min.,This is where OEE Starts!,Max Possible Product 1440 Min. Planned Downtime - 500 Min. Scheduled Production = 940 Min.,Max Possible Production,Scheduled Production,Availability Can you run it when its scheduled?,940 Min. Scheduled Production,-150 Min. Setup,790 Min.,-140 Min. Breakdow
12、ns,650 Min.,Performance Efficiency How fast do you run when you run?,650 Min. 185 Min. Minor Stoppages,- 40 Min. Speed Loss,-,465 Min.,=425 Min. Actual Production,Rate of Quality How much of what you make Is the customer happy with?,425 Min. Actual Production - 51 Min. Time Used Manufacturing Defect
13、ive Parts,374 Min. Good Product,Overall Equipment Effectiveness,= 39.8%,OEE =,量度指标 Metrics,整体设备效率 Overall Equipment Effectiveness (OEE) 可用效率 Availability 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
14、MTTR (Mean time to repair),可靠性 Reliability,MTTF = 平均故障时间间隔: 上次故障至本次故障之时间 Mean time to Failure ( the time from the previous breakdown to the current breakdown of machine. MTBF = 平均无故障时间: 从开机到故障停机之时间 Mean time between failure (the elapse time from the start up of the machine to the current breakdown o
15、f the machine MTTR = 平均维修时间: 从上次故障停机到重新开机之时间 the time from the previous breakdown to start up of the machine. 保养效率由MTBF及MTTF来衡量, 比例越高, 机况越好! Maintenance effectiveness is measured by MTBF/MTTF The greater the percentage the better!,TPM的目的：The Aim of TPM :,改善设备运行状况 To improve the equipment operating c
16、ondition 维持设备最佳性能与可靠性 To sustain equipment at an 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 Educatio
17、n & Practice,实施TPM十步骤 TPM Implementation -10 Steps,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 k
18、aizen focus. 5.根据OEE六大损失制定改善目标 Establish improvement 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 upd
19、ate check lists, train operators, and pursue 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
20、kaizen activity, setting more aggressive 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 Pe
21、rform minor repairs on machines 帮助解决问题 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 Establis
22、h cleaning and lubrication standards 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 equipm
23、ent correctly 判断污染 Measure deterioration : 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
24、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 selected maintenance tasks to operators,设备改善 Improve Equipment 支持可靠性及可维修性改善 Support R&M improvement 实施预测技术 Impl
25、ement predictive technologies 纠正设计不足 Correct design weaknesses 搞好供方合作 Partner with vendors,设备检查表 Equipment Inspection Checklist,初步清洁 Initial Cleaning 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? Any play in moving parts or fixture mounting section? 机器内部有无多余零件? Any
26、 unnecessary items located on the body of the machine? 润滑系统 Lubrication 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? Any damaged or missing grease nipples, oil caps, etc.? 供油装置、管路、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? Are oilers clean inside
27、 or out? 油标是否容易看见? Is the oil level easily visible?,设备检查表 Equipment Inspection Checklist,液压系统 Hydraulics 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? Is the pump emitting any abnormal noises? 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
28、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? Any strain or wear in high pressure hose connections? 电气系统 Electrical 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? Any missing or burned out pilot or indicator lights? 配电盘、电器箱有无线路图? Are there wiring dia
29、grams in the control panels or electrical boxes? 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?,设备检查表 Equipment Inspection Checklist,传动系统 Power Transfer Devices V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? Any damage, cracking or splittin
30、g of the belts? 滚柱链条的销轴与轴承之间有无足够润滑油? Is there sufficient lubrication between pins and bushings of roller chains? 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? 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? Any excess noise, heat or vibr
31、ation in gear mechanisms?,设备检查表 Equipment Inspection Checklist,螺母螺栓 Nuts and Bolts 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? Are nuts and bolts of the suitable types or sizes used? 垫片尺寸正确, 且类型相配吗? Are washers of proper size, and are they consistently used? 螺栓有从螺母凸出23
32、圈螺纹吗? Do bolts protrude 2 3 threads from the nuts? 气动系统 Pneumatics 截止阀及球阀漏气吗? Any stop valve, ball valve leaks? 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? Does any air flow through closed valves? 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? Are p
33、ipes and hoses orderly and readily identifiable? 压力表指示的都是正确设定的压力吗? Do pressure gauges clearly indicate the correct set pressure?,进行基本清洁 Perform Basic Cleaning,做好清洁检查 Clean to inspect 暴露隐藏不足 Expose hidden defects 找出脏污源头 Determine source of contamination 识别难于清洁之处 Identify hard to reach areas 准备蓝色标签工作
34、Prepare for blue tag exercise,消灭脏污源头 Eliminate Sources Of Dirt & Contamination,脏污原因 Causes of Contamination: 发生液体泄漏 Fluid leaks 碎片容器很差 Poor chip containment 工作不佳 Poor 5S practices 工作区有溅洒 Work area spills 过滤性能不好 Poor filtration 没有清洁标准 No cleaning standards 无工作自豪感 Poor work pride 环境问题恶劣 Environment,建立
35、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 Begin basic operator cleaning, inspecting and lubricating activities 制定临时标准 Establish provisional standards 进行重点训示 Create one point lesson 确定活动频次 Establish frequency of activities 月检、周检、日检清单Monthly, weekly and daily check list 制
36、做检查表 Develop check list,重点训示 One-Point Lesson,进行自主保养检查 Perform Autonomous Maintenance Inspection,制定详细的培训计划 Develop in depth training program 对工人就以下内容进行培训： Train operators in: 润滑作用/粘性分析 Lubrication/ Viscosity Analysis 气动系统 Pneumatics 液压系统 Hydraulic 电气系统 Electrical systems 驱动系统 Drive systems 修改目前的重点训示
37、, 加入检验检查工作 Revise existing one-point lessons to include inspection checks,培养工场整洁条理思想 Instill Orderliness & Organization,工场管理与控制 Workplace management & control 扩展团队活动, 做好设备以外的整洁工作 Expand team activities beyond equipment to other aspects of the process 搞好工场整洁, 实行目视控制，发现改善机会 (第4、5个S) Expose opportuniti
38、es for improved organization, orderliness and visual control (4th & 5th S) 进行5S评审 Perform 5S audits,整洁与条理 Organization & Orderliness,目视控制 Visual Controls,写出已做的活动, 展示取得的进步 Describes activities undertaken and shows progress 对比制定的标准, 量化取得的改善 故障停机、维修呼叫、停线时间等 Quantifies the improvements made against agre
39、ed metrics. e.g. (Breakdowns, defects, maintenance call-outs, line down-time, etc.) 细化实际的改善 Details the actual improvements made 记录待研究项目 Records issues to be reviewed: 没有答复的问题 Unanswered questions 需要支援的问题 Complex issues support required,问题公报 Problem Newspaper,问题公报 Problem Newspaper,生产保养完成率 PM Comple
40、tion Ratio,保养小组目视控制 Maintenance Group Visual Control,活动布告板 Activity Board,自主保养,全员生产保养活动 TPM Activities,进行TPM基础知识培训，评审准备工作 Train in TPM fundamentals & Review Pre-work,实施蓝色标签方法 Conduct Blue Tag Exercise 异常情况排序 Rank abnormalities 异常情况维修 Repair abnormalities,设备OEM手册评审 Review equipment OEM manuals 确定工人自主
41、保养路线, 制定检查表 Create Op. AM route & Check sheet,定义 / 实施标准化工作 Define & Implement Std Work 实现保养反馈循环 Implement feedback loop to maintenance 进行OEE表现公告 Implement OEE performance board,初步活动 自主保养 Initial Events Autonomous Maintenance,TPM的活动 TPM Activities,改善前活动 (专职队员) Pre-Kaizen Activity (Permanent Team),收集改
42、善活动一个月前的停机数据 Collect downtime data for one month prior to event 进行设备基本清洁活动 Conduct initial cleaning of equipment 收集设备规格、OEM手册、机器BOM及图纸 Gather machine specifications, OEM manuals, machine BOM, blueprints,改善活动 (改善团队成员) Kaizen Activity (Kaizen Team),进行两小时的观察 Conduct two-hour observation 清洁脏污源头, 贴上蓝色标签
43、Clean and Blue Tag sources of dirt and contamination 集思广益 按实施难易程度排序 Brainstorm ideas Prioritize according to implementation ease 实施解决方案, 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, 实现保养标准化 Standardize and develop Operator Autonomous Maintenance Routes, Check
44、 Sheets and One-point lesson 实行OEE表现公告制度 Implement OEE performance board 实施设备保养反馈循环 Implement equipment maintenance feedback loop,清洁检查 Clean To Inspect,改善前 Before 改善后 After,蓝色标签流程 Blue Tag Process,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 Write a blue tag for each ident
45、ified item 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签资料 Document Tag Information on Summary Chart 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 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, 保养人员要做好行动计划, 列明负责人
46、及时间要求 Maintenance completes 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 Team updates status of summary chart 在每月改善评审会议上, 专职队员评审总表状态 Permanent team reviews status of summary chart at monthly kaizen review meeting,蓝色标签 Blue Tag,蓝色标签,蓝色
47、标签,第1部分,第2部分,编号,编号,日期,日期,检查人,检查人,班次,班次,问题,问题,电气,机械,润滑,操作,仪器 / 控制机构,设备,其它,问题简述,电气,机械,润滑,操作,设备,仪器 / 控制机构,其它,问题简述, 继续见背面,问题可能影响,可使用时间,性能/速度,成品质量,环境,浪费,成本,安全,其它,改正行动计划,执行人,执行人,执行人,日期,日期,日期,工作单号,根本原因 / 行动, 更多见背面,完成日期,位置 / 系统 / 设备 / 零件代号,不足之处, 贴上标签 Deficiencies Tagged,蓝色标签总表 Blue Tag Summary Chart,机器名称 Ma
48、chine Name : Okuma LC20 B-344,影响程度 /修理难易程度分级 Impact / Difficulty Rating,目的 Used To: 发现所有浪费迹象, 提出可能解决方案 Capture waste information and potential solutions 按问题清晰程度及实施难易程度, 将解决方案进行排序 Rate / rank the solutions in regards to resolution of the issues and ease of implementation,标签排序矩阵图 Tag Prioritization Ma
49、trix,零件处理,影响 /解决的难易程度矩阵图 Impact/Difficulty Matrix,解决的难易程度,影响,自主保养检查表 AM Check List,日 一 二 三 四 五 六,检查液压系统有无泄漏,检修路线图 Inspection Route,1650吨冲压机检修路线路线图,路线 1 路线 2 路线 3,灰色表示楼梯或交叉路口,绿色的三角形区域代表根据检修表必须检查的地方,1650吨冲压机,钢胚炉,浸炉,重点训示 One-Point Lesson,重点训示 One-Point Lesson,目视工具 Visual Aids 检查设备时不能推测 Eliminate “guesswork” in determining equipment checks. 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 Added G