Manufacturing生产部门TPM全面生产性维护

1TotalProductiveMaintenanceManufacturing生产部门2ProcessCertificationTPMQCPCRootCause/CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinicActivityTotalProductiveMaintenanceACEManufacturingQualifyingLevel3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产准备标准化作业防误措施市场反馈分析6S质量诊断行动全面生产性维护ACE生产部门合格水平4TotalProductiveMaintenanceisanequipmentmanagementstrategythatimprovesequipmentefficiency.全面生产性维护是一种设备管理策略以提高设备效率。Or,inotherwords...Treatingtheequipmentlikeitisyourown!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5TPMKeyConceptTPM的重要概念•Leftneglected...EquipmentBreaksDown•如果不重视…设备很快就会坏TPM’sfocusistopreventproblemsbeforeequipmentbreaks.TPM的焦点是要在设备出故障以前防止问题出现。Inthepast,maintenancefocusedonfixingequipmentafteritbroke.过去，维护工作总是集中在设备坏了以后对其进行修理。6TotalProductiveMaintenanceisaNewWayofWorking全面生产性维护是一种全新的工作方式TPMAttitude:TPM态度：“Weareallresponsibleforourequipment.”“我们所有人对我们的设备负责。”OldAttitude:过去的态度：“Ioperate,youfix.”“我操作，你修理。”“Ifix,youdesign.”“我处理，你设计。”“Idesign,youoperate.”“我设计，你操作。”7HiddenDefects隐藏的问题Failures故障Wear,play,slackness,leakage,dust,dirt,corrosion,deformation,adherenceofrawmaterials,surfacedamage,cracking,overheating,vibration,noise,andotherabnormalities.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。TipoftheIceberg冰山的顶端8TypicalCausesofMachineBreakdown典型的机械故障原因Failuretoaddoil.没有加油Gritandchipsinrevolvingorslidingparts旋转或滑动零件中的砂砾和碎片Contaminationofsensors,contactsandConnectors传感器、触敏器、连接器污染Dirtanddustoncoolingfan冷却风扇上有灰尘和污垢ComponentFailure组件失灵Iwonderwhat’sgoingtofailnext?我在想下面还会出什么问题呢？9TPMTechniquesTPM技术NormaloperatingRange正常操作范围Danger!危险！•SimplifyandDocumentTPMActivities.•简化并记录TPM行动•Usevisualtechniquestoindicatewhat’sright/what’swrong.•运用直观技术来演示什么是对的/什么是错的。–PMCompleted?生产性维护完成了吗？–Pressuregage压力计–Sightglass视镜–Arrowsformotorrotationandfluidcirculation马达旋转和润油指示箭头–markingsforsparepartsandfluids.–备用零件和润滑油记号MakingPMdevicesmoreaccessible.•使生产性维护设备更容易获得–Filters,fittingsmademoreaccessible过滤器、各种装置–Transparentpanelstofacilitateinspection明了易读的仪表盘便于检查10TPMBenefitsTPM的益处•Reducedmaintenancecosts•减少维护费用–Breakdownmaintenanceis10timesmorecostlythanplannedmaintenance–故障维修费用是有计划进行维护费用的10倍以上•Enhancedsafety提高安全性–Findexposedwires,openbelts,missingguards,loosehardware–发现暴露在外的电线、松开的安全带、缺少防护、松开的部件•Reducedwaste减少浪费–Preventslossoflubricant,compressedair–防止润滑油、压缩空气的浪费•Improvedquality提高品质–Equipmentmorecapableofholdingtolerance–设备抗性增强•Lessdowntime,longerlife缩短停工时间，寿命更长1112TPMQualifyingActivities•ACEElementAwarenessTraining•LockOut/TagOutawarenesstrainingavailableforallemployees(withannualrefresher)•Operatorsofhighhazardequipmentinformedofmachinespecifichazards•Assessmentofmachinespecificsafeguarding(SP-008)issues•LockOut/TagOutEquipmentAvailableReviewOnlyActionItems•AssessallEquipmentA,B&C•ImplementwrittenLockOut/TagOutprocedure•Walkaroundsafetycheckon100%ofA/Bequipment•PMSchedulefor100%ofA/Bequipment•Cleaningon100%ofA/Bequipment•Trackdowntimehistory•Toptendowntimeequipmentidentified1212项TPM合格行动•ACE内容认知培训•锁定/标识认知培训，针对所有员工（每年的复习进修者）•告知高危险设备操作员有关机器的详细危险•机器的特殊防护措施（SP-008）问题评估•可用的锁定/标识设备仅用于检查行动内容•评估所有A,B&C类设备•完成写好的锁定/标识程序•所有A/B类设备的安全巡查•所有A/B类设备的生产性维护进度表•清洁所有A/B类设备•追溯停工历史•确认的十大停工设备13PURPOSEofLockout/Tagout锁定/标识的目的Topreventyouorsomeoneelsefrominadvertentlyturningapowersourceonandcausingapotentialinjuryorevendeath.以防你或它人意外开动电源而造成可能的伤害甚至死亡Lockout/TagoutReview:锁定/标识检查14LockoutDevice锁定设备Alockorotherdevicethatutilizesapositivemeans,toholdanenergyisolatingdeviceinasafepositionandtherebypreventingtheenergizingofamachineorpieceofequipment.一把锁或其它设备，用于使电源设备隔离装置处于一安全的状态，以防止机器或设备的一部分带电。Lockout/TagoutReview:锁定/标识检查15TagoutDefinition标识的定义•Theprocessofsecurelyfasteningatagorprominentwarningsigntoindicatethatboththeenergyisolatingdeviceandtheequipmentbeingcontrolled,mustnotbeoperated.•是将一标签或明显的警告标志紧附于设备上以表明不能对电源隔离设备及处于控制下的设备进行操作。•Thetagwillalsoincludethenameofthepersonwholockedouttheequipment.•该标签应有锁定该装置的人的名字。Lockout/TagoutReview:锁定/标识检查16WARNING警告•NEVERACCEPTLOCKOUTSKEYSFROMANYONE.•决不要从它人处接受锁定设备的钥匙。•THEASSOCIATERESPONSIBLEFORAPPLYINGTHELOCKORTAGISTHEONLYPERSONAUTHORIZEDTOREMOVETHELOCKORTAG.•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/TagoutReview:锁定/标识检查17ACTIONITEM1:AssessAllEquipment行动内容1：评估所有设备•By“Equipment”wemeananymachinethatwasacapitalexpenseandhasadepreciativevalue.Oranymachinethatisimportanttoyourcell.•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。WeCategorizeallEquipmentbasedonhowUniqueandCriticalitistoensurewefocusattentionontherightequipmentfirst.Payspecialattentiontobottleneckequipment.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优先放在正确的设备上。对瓶颈设备给予特殊的关注。Equipment设备18CategoryA:Criticalequipmentforwhichanalternatemachineisnotfeasible,because:A类：不能用其它设备替代的关键设备，因为：–Noalternateexists,or–无替代设备，或–Thealternateisusuallyunavailableduetoutilization,or–该替代设备通常正被使用而不能获得，或–Itwouldbetoocostly/timeconsumingtotransitiontothealternate–太贵/需花太多时间进行替换•CategoryC:Equipmentforwhichitisrelativelyeasytofindareplacementoralternate•C类：相对容易用其它设备替代的设备–Includesmostoff-the-shelfequipment–包括最常用的设备–Typicallycost$2,500–费用低于$2,500–Standardspareparts(likedrivemotors)areavailableoff-the-shelf–可获得的常用标准备件（如驱动马达）•Ca