精益生产之全面生产维护TPM中英文版.ppt

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1、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,RD011202,Total Productive Maintenance(TPM),TPMTPM Team OrganizationOverall Equipment Effectiveness TPM Phases,RD011202,Total Productive Maintenance(TPM),3,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

2、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&R,Cp&Cpk供应链加速器分析多变动图i盒状图交互作用图回归分析ANOVAC&E 矩阵图FMEA,脑力风暴拉系统减少设置TPM流程图标

3、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 1-12-02,Total Productive Maintenance(TPM),4,Lean Six Sigma Improvement Process Road Map,Analyze,Control,Improve,DefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key Met

4、ricsComplete PDF,MeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability Analysis,AnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPriorit

5、ize Root CausesConduct Root Cause Analysis on Critical Xs,ImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot Solution,ControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future Owners

6、Identify Project Translation Opportunities,Measure,Define,Project ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad Charts,Process MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto Cha

7、rtsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&R,Cp&CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEA,BrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsG

8、antt Charts,Check SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-Yoke,Revised 1-12-02,Total Productive Maintenance(TPM),5,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;实施维护审查,Total Productive Maintenance(TPM),6

9、,Learning Objectives,Learn 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 predictive maintenance as a diagn

10、ostic toolImplement maintenance audits,Total Productive Maintenance(TPM),7,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),8,Whats in It for Me?,Optimized process operations and maintenanceA method to replace the traditional appro

11、ach 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 performance,Total Productive Maintenance(TPM),9,全面生产维护(TPM),定义:一种用

12、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),10,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 Maintenance.,Total P

13、roductive Maintenance(TPM),11,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),12,TPM,Achieve zero equipment breakdowns and zero defects through preventionEstablish prevention byMaintaining normal conditionsEarly detection of abnormalitiesQuick response,Total

14、Productive Maintenance(TPM),13,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),14,Traditional Approach“Re-Active Maintenance”,Maintenance“WE FIX”Perform all maintenance activitiesPe

15、rform“Fire Fighting”maintenance when a machine breakdown occursOrder and administer all tooling,supplies,etc.Perform Preventive Maintenance,Manufacturing“WE OPERATE”Generally does not perform any maintenance activitiesContacts maintenance when a machine breakdown occursInactive during maintenance ac

16、tivities“Run it till it breaks”,Total Productive Maintenance(TPM),15,主要概念,定期保养是一种基于时间长短或使用状况对设备进行检修的方法.在指定时间或在使用空档间对设备实施检修作业以防止设备发生故障.定期保养计划,预测性保养是一种基于设备状态的维护方法.根据可视信号或检测技术的情况来实施保养以防止设备发生故障.振动分析激光探测超声波检测发电机测试热感应油况分析,Total Productive Maintenance(TPM),16,Key Definitions,Preventive Maintenance is a tim

17、e or usage based method of maintaining equipment.Maintenance activities are performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occurring.PM Schedules,Predictive Maintenance is a situation based method of maintaining equipment.Maintenance activiti

18、es are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring.Vibration AnalysisLaser MeasuringUltrasoundGenerator TestingThermographyOil Analysis,Total Productive Maintenance(TPM),17,现状分析和团队组织,评估当前的操作条件:机器利用率,生产率等;维修费用(配件和人工)对实现TPM的各项

19、工作进行优先次序评估潜在TPM倡导者及团队成员的实力挑选TPM倡导者及团队成员建立初始的实施专门小组确定团队目标,Total Productive Maintenance(TPM),18,Present State Analysisand Team Organization,Assess Current Operating ConditionsMachine utilization,productivity,etc.Maintenance repair costs(parts and labor)Prioritize order of TPM effortsAssess capabilitie

20、s of potential TPM Champions and Team MembersSelect TPM Champion and Team MembersEstablish initial kick-off workshopEstablish team goal,Total Productive Maintenance(TPM),19,典型的设备评价指标,利用率:设备实际运转时间与总的可利用时间的比率;=实际运行时间/可运行时间效率:实际产量与标准产量的比率=(实际产量/小时)/(标准产量/小时)产出:用一特定时间段的产量来衡量=磅/小时,件数/小时,Total Productive

21、Maintenance(TPM),20,Typical Operational Process Measurements,Utilization:The ratio of equipment actual operating time to the total available operating time=Actual Operating Time/Available TimeEfficiency:The ratio of actual product produced to a standard=(Actual Parts/Hour)/(Standard Part/Hour)Output

22、:Measure of output over a specified time period=lbs/hr,pieces/hr,Total Productive Maintenance(TPM),21,设备综合利用率OEE,设备综合利用率（OEE）是衡量一台设备按计划速度生产出合格产品的时间占全部时间的百分比.,Total Productive Maintenance(TPM),22,Overall Equipment Effectiveness,Overall Equipment Effectiveness(OEE)is the measure of the percent of time

23、 a piece of equipment is producing quality product at the designed rate.,Total Productive Maintenance(TPM),23,OEE分解:六大浪费,故障及轻微故障使设备中断运行的时间超过10分钟的故障或者中断时间少于10分钟的轻微故障.设置时间浪费任何与设备调整,装配,清洁相关的作业.,机器空转浪费设备在运转却没有用来生产产品所耗用的时间.速度浪费由于设备或产品的异常造成设备以低于标准速度或所设定的速度运转.,品质原因浪费为确保设备产出品的品质而采取相关的作业(过程中检查).返工浪费用于返修产品或生产

24、出报废产品所耗用的时间.,Total Productive Maintenance(TPM),24,OEE Breakdown:The Six Big Losses,Breakdowns and Minor StoppagesMalfunctions causing equipment to stop processing greater than 10 minutes(breakdowns)or less than 10 minutes(minor stoppages)SetupAny activity related to equipment changeover,setup,or cle

25、aning.,IdlingTime equipment is running but not producing product.Speed LossesEquipment operating at less than standard or design speed due to equipment/product abnormality,Quality FactorsActivities related to ensuring the quality of the product produced on the equipment(in-process checks).Rework Los

26、sesThe time taken to re-process product or time take to produce un-usable product.,Total Productive Maintenance(TPM),25,六大浪费的识别练习,Total Productive Maintenance(TPM),26,Six Big Losses Identification Exercise,Total Productive Maintenance(TPM),27,OEE的计算原理,承载时间(LT),设备运转总的可利用时间=40 hrs,可用水平(AL),运行水平(OL),质量

27、水平(QL),OEE,73%x 91%x 80%,26.3-3.1-2.1=80%26.3,28.9-1.5-1.1=91%28.9,质量原因,机器故障及轻微故障,行政事务/非作业时间,机器设置与调整,速度损失,机器空转,返工及报废,40-3.1-3.8-4.2=73%40,OEE=53%,AL HRS=40-3.1-3.8-4.2=28.9 hrsOL HRS=28.9-3.1-1.1=26.3 hrsQL HRS=26.3-3.1-2.1=21.1 hrs,Total Productive Maintenance(TPM),28,Calculating OEE Elements,Loadi

28、ng Time(LT),Total Hours Available for Equipment Operation=40 hrs,AvailabilityLevel(AL),OperatingLevel(OL),QualityLevel(QL),OEE,73%x 91%x 80%,26.3-3.1-2.1=80%26.3,28.9-1.5-1.1=91%28.9,QualityFactors,BreakdownsMinor Stops,and Admin.,Setup,Speed Losses,Idling,Rework andScrap,40-3.1-3.8-4.2=73%40,OEE=53

29、%,AL HRS=40-3.1-3.8-4.2=28.9 hrsOL HRS=28.9-3.1-1.1=26.3 hrsQL HRS=26.3-3.1-2.1=21.1 hrs,Total Productive Maintenance(TPM),29,世界级的OEE性能水平,承载时间(LT),同步计划运转时间及生产性防护时间,可用水平(AL),运行水平(OL),质量水平(QL),OEE,90%x 95%x 99%,质量原因,机器故障及轻微故障,行政事务/非作业时间,机器设置与调整,速度损失,机器空转,返工及报废,OEE=85%是世界级的性能水平,AL始终保持在 90%以上,OL维持在 95%以

30、上,QL不低于 99%,Total Productive Maintenance(TPM),30,World Class OEE Performance,Loading Time(LT),Operation Time and PM Time is scheduled synchronizing the two,AvailabilityLevel(AL),OperatingLevel(OL),QualityLevel(QL),OEE,90%x 95%x 99%,QualityFactors,BreakdownsMinor Stops,and Admin.,Setup,Speed Losses,I

31、dling,Reworkand Scrap,OEE=85%is World Class Performance,The AL is consistently kept at or above 90%,The OL is maintained at or above 95%,The QL is at or above 99%,Total Productive Maintenance(TPM),31,使设备恢复到可靠状态,消除故障,开发PM维护保养资料库,消除缺陷,阶段 I,阶段 II,阶段 III,阶段 IV,TPM 阶段,Total Productive Maintenance(TPM),32

32、,Return Equipmentto Reliable Condition,EliminateBreakdowns,Develop PMInformation Database,EliminateDefects,PHASE I,PHASE II,PHASE III,PHASE IV,TPM Phases,Total Productive Maintenance(TPM),33,六大团队活动,1.通过小规模的小组活动来提高机器的正常运行时间,消除造成停工的主要根源:机器的启动损失机器的故障损失待料损失和生产安排不当带来的停机损失2.使操作员熟练地参与如润滑,清洁,故障检验等基本的保养维护.,T

33、otal Productive Maintenance(TPM),34,Six Team Activities,1.Use small group activities to improve machine uptime by eliminating the major sources of downtime.Startup LossesBreakdown LossesMaterial and Scheduling Losses2.Involve the machine operators as well as skilled trades in basic preventative main

34、tenance such as lubrication,cleaning,and inspection for defects.,Total Productive Maintenance(TPM),35,六大团队活动(续上页),3.使用诸如振动分析类的预测工具摈弃过去那种反应式的维护模式4.增强对设备的认知和了解以提高生产效能,减少停工时间;5.使供应管理和生产调度协同工作以确保持续稳定的原材料供应,避免停机待料;6.规划人员配备以确保瓶颈设备处的满员运作,Total Productive Maintenance(TPM),36,Six Team Activities(Cont.),3.Uti

35、lize predictive tools such as vibration analysis to move past reactive type maintenance4.Increase awareness and knowledge of equipment to improve productivity and reduce downtime5.Work with Supply Management and Production Control to insure a constant flow of raw material is available to preclude id

36、ling.6.Develop manning schedules that insure that bottleneck machines are fully staffed,Total Productive Maintenance(TPM),37,TPM的益处,提升操作员的参与感使设备恢复至更高的性能水平发现并消除早期的设备隐患减少总的制造成本减少浪费 在保养设备方面树立荣誉感促进维护和生产部门之间的相互尊重与合作,Total Productive Maintenance(TPM),38,Benefits of TPM,Promotes operator involvementRestore

37、s equipment to a higher performance levelUncover and eliminate premature equipment failuresReduce total manufacturing costsReduces waste Builds a sense of pride in maintaining the equipmentPromotes cooperation and respect between maintenance and production,Total Productive Maintenance(TPM),39,职责范围,精

38、益6Sigma团队倡导者/发起人TPM团队操作员现场主管维护人员,Total Productive Maintenance(TPM),40,Areas of Responsibility,Lean Six Sigma TeamChampion/SponsorTPM TeamOperatorSupervisorMaintenance,Total Productive Maintenance(TPM),41,精益6Sigma团队的任务,确定一个TPM项目的需求收集有关维护成本,延迟(时延或操作延迟,设备利用率以及质量问题的历史数据与操作员进行深入沟通以了解他们的期望,Total Productiv

39、e Maintenance(TPM),42,Lean Six Sigma Team Role,Determine the need for a TPM ProjectGather history of maintenance cost,delay,machine availability,and quality problemsInterview Operators to get their prospective,Total Productive Maintenance(TPM),43,现场活动组成TPM团队负责设备维护的人员操作员一线管理人员准备必要的装备帮助TPM团队诊断异常协助跨功能培

40、训收集整理故障标牌的拷贝并生成工作明细表提供人力资源方面的支持,精益6Sigma团队的任务,Total Productive Maintenance(TPM),44,Lean Six Sigma Team Role,On floor activitiesAssemble the TPM TeamMaintenance personnelOperatorsFirst line supervisionProvide necessary equipmentHelp team diagnose abnormalitiesAssist skilled tradesCollect copies of de

41、fect tags and generate a work listProvide people resources,Total Productive Maintenance(TPM),45,倡导者/发起人的角色,一旦完成现场工作,接下来将:形成工作任务并跟踪其完成情况协助建立和引入正确的定期维护明细表协助维持改善结果评估设备综合利用率OEE展示TPM的改善的成就,Total Productive Maintenance(TPM),46,Champion/Sponsor Role,Upon Completion of On Floor EventGenerate and track compl

42、etion of work ordersAssist in creation and posting of accurate Periodic Maintenance List Assist in sustaining the gainsEvaluate Overall Equipment EffectivenessDisplay TPM improvements,Total Productive Maintenance(TPM),47,现场主管的角色,指导并推广TPM概念监控现场的设备管理,保养及机器清洁工作的进行激发操作员的主人翁意识对操作员授权为TPM活动提供时间方面的准备促进生产与维护

43、双方的合作,Total Productive Maintenance(TPM),48,Supervisors Role,Coach and promote TPM ConceptsMonitor ongoing housekeeping and machine cleanlinessPromote Operator ownershipEmpower Operators Provide time for TPM activitiesPromote cooperation between Production and Maintenance,Total Productive Maintenance

44、(TPM),49,维护人员的角色“专业的管理者”,有计划的实施所有的定期保养并根据需要采取维修措施;使用振动分析,磨损度分析,热感应等预测工具;建立维护设备的保养记录与操作员协同工作并提供技术支持执行设备大修,综合调试负责执行一些特殊技能的任务,风险安全性高的作业促进TPM,Total Productive Maintenance(TPM),50,Maintenance Role“The Specialized Caretakers”,Perform all planned preventative maintenance and take corrective action as neede

45、dUse predictive tools such as vibration analysis,wear particle analysis,and thermographyDocument equipment maintenance historyCooperate with Operators and provide technical assistancePerform equipment overhaul,complex adjustmentsProvide special skill tasks,high safety risk tasksPromote TPM,Total Pro

46、ductive Maintenance(TPM),51,操作员角色“一线管理者”,清洁和缺陷检查执行基本的润滑,多点检测的工作按照核准清单的项目进行定期保养按计划执行日常清洁和整理识别刚刚发生的设备异常根据需要协助维护人员进行维修执行基本的调试工作改善提案促进TPM,Total Productive Maintenance(TPM),52,Operators Role“The First Line Caretaker”,Clean and inspect for defectsPerform basic lubrication,multi-point inspectionPerform Per

47、iodic Maintenance per approved ListPerform routine cleaning and housekeeping as scheduledIdentify equipment defects as they ariseAssist Maintenance with repairs upon requestPerform basic adjustmentsSuggest improvementsPromote TPM,Total Productive Maintenance(TPM),53,全面生产维护的七大步骤,1.完成初始的机器清洁和检查2.识别机器的

48、缺陷和泄漏并加以标示3.建立操作员及维护人员的定期检测的PM计划4.指导操作员使用正确的保养方法5.指导维护人员使用正确的保养方法6.贯彻现场5S管理和组织活动7.监控OEE并鼓励大家合作,Total Productive Maintenance(TPM),54,The 7 Steps of Total Productive Maintenance,1.Perform initial machine cleaning and inspection2.Identify and tag machine defects and leaks3.Develop Operator and Maintena

49、nce PMs4.Instruct Operators in proper PM techniques5.Instruct Maintenance Staff in proper PM techniques6.Implement 5S Housekeeping and Organization7.Monitor OEE and encourage cooperation,Total Productive Maintenance(TPM),55,TPM 安全常识,遵守/使用停工现场标牌警示程序正确的起重方法用电安全操作规范劳保装备手套工作鞋 护目镜防尘口罩 耳塞,Total Productive

50、 Maintenance(TPM),56,TPM Safety Habits,Follow/UseLockout Tagout ProcedureProper Lifting TechniquesElectrical Safety GuidelinesPersonal Protective EquipmentGlovesSafety Shoes GogglesRespirators Hearing Protection,Total Productive Maintenance(TPM),57,TPM 步骤1,初始的机器清洁和检查目的:识别需修理处并标示缺陷执行:彻底清洁机器-团队所有成员参与并