全员生产保养08PTPM08Q3bil.ppt

全员生产保养Total Productive Maintenance,目录 Table of Contents,TPM概略 TPM OverviewTPM目的 The Aim of TPMTPM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 QualityTPM改善活动 TPM Kaizen ActivitiesTPM活动进阶 Advanced TPM Activities,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OperatorAutonomousMaintenance,预防保养Preventive Maintenance,经理支持功能ManagerSupportFunction,工程设备设计改善Eng.Equip.DesignImprovement,品质改善QualityImprovement,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,满足节拍速度Achieve Takt Rate at the highest machine effectiveness,TPM与精益西格玛流程 TPM and LeanSigma Process,精益西格玛LeanSigma Process,及时生产JustinTime,自働化Jidoka,畅顺生产 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 conditions制程重复Process Repeatability防错装置Mistake Proofing,实现流畅生产,必须实行TPMTPM 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&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,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 MTTR(Mean time to repair),TPM的目的：The Aim of TPM:,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PlanningMaintenance,预防工程PreventiveEngineering,品质Quality,教育与行动Education&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OEEMeasure 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 kaizen 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 update 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 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 Perform 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 systemfor 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Establish 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 equipment 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Implement 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 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 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?电器系统 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 diagrams 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 DevicesV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 splitting 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 vibration 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 pipes 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 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 制做检查表 Develop check list,重点训示 One-Point Lesson,1.0 目的/范围:根据3600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:工人,3.0 安全:标准的工人保护设备:防护眼镜,听觉保护用具,手套,钢头鞋,4.0 工作指示,第1步:本工作指示用于与3600路线检查单有关的工作,第2步:本工作指示用于3600吨冲压机周围的检查工作35,第3步:检查模具加热炉温度及设定值。绝对最低设定值应为800度,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,加入检验检查工作Revise existing one-point lessons to include inspection checks,灌输工场整洁条理思想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 opportunities 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 agreed 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ProblemNewspaper,问题公报ProblemNewspaper,生产保养完成率PM Completion 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 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 identified 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 Machine 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 Matrix,制程:通讯技术支持呼叫流程,障碍/浪费,根本原因,解决方案/影响,难易程度,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Impromptu,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,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,自主保养检查表,90吨冲床,日 一 二 三 四 五 六,项目说明,工人日检,工人周检,日 一 二 三 四 五 六,日期 备注:说明潜在问题,员工 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。,检查路线 Inspection Route,1650检查路线流程图,路线 1 路线 2)路线 3,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,1650吨冲压机,钢胚炉,重点训示 One-Point Lesson,1.0 目的/范围:根据3600路线检查单具体检查步骤制定详细的工作指示,2.0 责任:工人,3.0 安全:标准的工人保护设备:防护眼镜,听觉保护用具,手套,钢头鞋,4.0 工作指示,第1步:本工作指示用于与3600路线检查单有关的工作,第2步:本工作指示用于3600吨冲压机周围的检查工作35,第3步:检查模具加热炉温度及设定值。绝对最低设定值应为800度,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 Green Triangles to Equipment 绿色三角形表示要按清单检查的地方Green triangles represent areas that are to be checked in accordance with checklist.,Press Operator,步骤1:取一份空白检查表,表格编号:2750_RC,步骤2:检查第0-1点坯料锯确保进料辊筒转动自由,步骤3:检查第0-2点坯料锯检查锯片冷却液是否足够。如果不够一半,则予以补充,突显检查点 Make Inspection Point Visible,突显检查点(续)Make Inspection Points Visible(Continue),简化检验检查 Make Inspection Checks Simple,自主保养目视化 Make AM Checks Visible,目视工具 Visual Aids不要主观Remove Subjectivity 设立最大/最小标准Establish MIN/MAX Levels 充当塞规作用,工人看到仪表标签就知道压力范围或液体高度是否正确Used as a go/no-go device,the gauge labels let the operator know if the pressure ranges and fluid levels are correct.,活动公告板 Activity Board,自主保养,根本原因分析Conduct Root Cause Analysis 因果法Cause&Effect5个为什么5 Whys 比较分析Comparative Analysis,TPM改善进阶 解决问题的工具Advanced TPM Kaizen Problem Solving Tools,全员生产保养活动 TPM Activities,改善公报 改善活动后的活动清单Kaizen Newspaper Post Event Action List,