TPM方法(3)

TPMMETHODTPMGLOBALINDICATOR:THETRSTRS=QualityproductiontimeOpeningtimeTRS=NumberofgoodpartsproducedxCycletimeOpeningtimeCycletime=Initialreference+improvementsInitialref.=MinimumtechnicaltimeTPMRELIABILITYINDICATORAverageofgoodworkingtimeMTBF=ActualproductiontimeNumberofrealstoppagesTPMRELIABILITYINDICATOR=MTBF(meantimebetweenfailure)Itistheaveragedurationinminutesduringwhichthemachineortheinstallationfunctionedwithoutanystoppages.Thestoppagesare:-machinebreakdowns-breakdownsrelatedtotools-breakdownsrelatedtotheproduct-stoppagesforchange-overs(usedorbroken)-stoppagesforfrequentadjustments-stoppagesforinspection(SPCsampling)-stoppagesformaintenanceStoppagesfortoolchange-oversarenottakenintoaccountTPMBREAKDOWNSANDMICRO-STOPPAGES:BREAKDOWNS–Stoppages=5mins–Notoften–Systematicallynoted–Stoppageaffectstheentireworkinggroup–Interventionofanexpert–Researchnecessarybeforestart-up–IdentifiablecausesMICRO-STOPPAGES–Stoppages5mins–Often–Notnoted–Littleornoperceptionbythegroup–Easystart-upwithouteliminationofthecause(suppressionoftheeffect)–Nonidentifiedcauses–Littlemotivationtoeliminatethembecauselittleperceivedimpactonproduction–StronglyinvolvetheoperatorsandautomaticinstallationpeoplefortaskswithoutAddedValueTPMDATACOLLECTIONSBREAKDOWNRECORDSOFTHELAST6MONTHSPRODUCTIONNOTEBOOKSOPERATOREXPERIENCETHEDATEOFTHELASTTECHNICALMODIFICATIONDONEONONEPARTOFTHEMACHINE–Paretoofunsolvedbreakdownsofthelast12months–Eliminatefromthisdatabasethesolvedbreakdowns–Priorityistosolvebreakdownsthatrepresentthehigheststoppages–Repetitivebreakdownsmustbehighlightedbreakdown1breakdown2breakdown3breakdown4breakdown5breakdown6TPM:BreakdownsParetoanalysisofbreakdownsTPM:BREAKDOWNSTREATMENTMETHODOLOGYRegistertheanomalies(includingthebreakdowns)CarryouttherepairsDefinetheactionstoavoidrecurrenceConfirmthecauseSteering:SupervisorExecution:MaintenanceProf./WorkshopTechnicianMethod:ManagementofoperationsandsparepartsSteering:SupervisorExecution:MaintenanceProf.+TA+SupervisorMethod:1h30meetingonceaweek,5WhyoreventualcreationofaPSGSteering:SupervisorExecution:OperatorsMethod:RecordonanotebooknearthemachineorinstallationastheyoccurPROCESSPeopleConcernedMethodsKnowthehistoryofbreakdownsandcurrentworkTpsinterv.Resp.0to5mins:GAP5to15mins:Tech15mins:Expert30mins:Maintenance2134TPM:BREAKDOWNSTREATMENTMETHODOLOGYCreateormodifyifnecessarytheroutinesheetofpreventivemaintenanceApplythenewstandardSteering:SupervisorExecution:MaintenanceProf.+SupervisorMethod:Updateandvalidationofroutinesheet.Steering:SupervisorExecution:Operators+MaintenanceProf.Method:Followingthelevelofmaintenance,definethetrainingneedsandtrainthecontributorsSteering:AnimationtoreachobjectivesExecution:Applicationofformalisedinstructions56Thehistoryofbreakdownsistheback-updocumentoftheprocess,itisfoundonthemachineandisavailableforeverybody.ItiscompletedbythepersoncarryingoutthegiventaskTPM:BREAKDOWNSWEEKLYMEETING–SUBJECT:breakdownsencounteredduringtheweek–PARTICIPANTS:supervisorandmaintenancetechnician–GOAL:ensurethatthedefinitivemeasureshavebeenimplementedtoavoidanyrecurrenceofbreakdowns–PLAN:weeklybreakdowninventoryforthepastweekexaminecausesactionstobeimplementedTPMMICRO-STOPPAGES:CHARACTERISATION–Shut-down5mn–Often–Norecords–Littleornoperceptionbythegroup–Easystart-upwithouteliminationofthecause(suppressionoftheeffect)–Unidentifiedcause–Littlemotivationtoeliminatethembecauselittleperceivedimpactonproduction–StronglyinvolvestheoperatorsandautomaticinstallationpeoplefortaskswithoutAddedValueTPM:MICROSTOPPAGESTREATMENTMETHODOLOGYFromthenotedeffect,definethediagnosismethodofcausesRegisterthemicro-stoppagesSelectthemicro-stoppagetobetreatedQuantifythecauses(counting)Identifythepossiblecausesofthemicro-stoppagePROCESSPeopleConcernedMethodsSteering:SupervisorExecution:Operators,Supervisor,MaintenanceandManufacturingEngineeringTechniciansMethod:meetingsontheshopfloorwithproblemsolvingtools(Pareto-BrainStorming-5Mcause-effectdiagram-5Why's)Steering:SupervisorExecution:TechniciansandOperatorsMethod:Useofexhaustivefilmofallthemachineanomalies(withfollow-upofhumanintervention).ParetoSteering:SupervisorExecution:OperatorsMethod:Notedonnumberedworkstationform(counting)Steering:SupervisorExecution:MaintenanceExpertMethod:Formaliseandtraintheoperatorindiagnosis21354SelectthemachinesTPM:MICROSTOPPAGESTREATMENTMETHODOLOGYCreateormodifyifnecessarytheroutinesheetofpreventivemaintenanceSelectthecausestobetreatedinprioritySet-upthesolutionsLookforsolutionsContinuewiththecountingofcausesofthemicro-stoppageSteering:SupervisorExecution:ManufacturingEngineeringTechnician-MaintenanceProf.-OperatorsMethod:Dependingonthelevelofmachinemodificationand/orlevelofmaintenanceDefinethetrainingneedsandtrainthecontributorsSteering:SupervisorExecution:PSGmembersMethod:Pareto-Balancing-BrainstormingSteering:SupervisorExecution:OperatorsMethod:Notedonworkstationform(counting)Applythenewstandard97610811TPMROLEOFTHEOPERATORPREVENTIVEMAINTENANCE–CarryoutproductionoperationscorrectlyandsetupthemachineDoinspectionofthema