全面生产性维护---TPM

BeltonConfidential‹#›TowardsOperationalExcellenceLEANPractitionerProgramTotalProductiveMaintenance全面生產性維護BeltonConfidential‹#›VisualManagement目視管理ValueStreamMapping价值流程圖MaterialControl物料控制TPM全面生產性維護LayoutOptimization/Cell布局優化／CellSMED/QuickChangeover快速切換ErrorProofing防錯法PerformanceMetrics績效指標TheoryOfConstraints瓶頸理論LeanDiagnostic精益診斷ChangeM&WasteE改變觀念&消除浪費LeanOverview精益概述LeanTools精益工具TherearemanytoolsandtechniquesintheLean‘toolbox’,allsuitedtodifferentapplicationsandcircumstances.在LEAN工具箱中有許多工具和技巧,它們可以用于各種不同的情況.BeltonConfidential‹#›TrainingObjectives培訓目的Aftercompletionofthistrainingyoushouldbeableto完成此課程后妳應該能夠:UnderstandwhatTPMis理解TPM是什么HaveanoverviewofAutonomousMaintenanceactivities有自主維護的概念UnderstandEquipmentLosses理解設備損失AbletofocusonequipmentimprovementusingOEE能用OEE來關注設備的改善BeltonConfidential‹#›1950sMAINTENANCEBreakdown事后維護“停机維修”1960sPREVENTATIVEMAINTENANCE預防維護“Ioperate...youfix””我操作...你維修”1970sPRODUCTIVEMAINTENANCE生產性維護“RecognitionofEquipmentMaintenanceIssuesatPlantDesignStage”“在設計階段強調設備維護”1980sTOTALPRODUCTIVEMAINTENANCE全面生產性維護“ProductiveMaintenancewithTotalEmployeeParticipation”“全面維護,全員參与”Theimportanceofexcellent‘assetstewardship’isnowrecognizedbytheworld’sleadingmanufacturingcompaniesasacriticalsuccessfactor.卓越的固定資產管理目前已被世界領先的制造公司作為一個關鍵的成功因素Introduction介紹BeltonConfidential‹#›什么是全面生產性維護(TPM)?TotalProductiveMaintenanceorTPMinshortisaconceptofoptimizingequipmenteffectivenessthroughtotalemployeeinvolvement全面生產性維護(簡稱TPM)是通過全員參与來改善机器一生的總性能.TPMaimstoreducestatisticalvariabilityonequipmentbyimprovingtheequipmentperformanceinordertoachieveamorerobustandpredictableprocessTPM目的在于改善机器的績效,降低机器的統計波動,來達到更可靠的工序.Production,maintenance&engineeringcrewsupporteachotherandunderstandhowtheirrolesinteractinordertoworktowardsZeroBreakdown,ZeroAccident,ZeroDefects生產﹑維修和工程的同事互相支持﹐理解相互的職責﹐共同達到零故障﹑零事故﹑零不良﹒BeltonConfidential‹#›TPM-Potentialbenefits潛在好處•Productivity生產力IncreasedLaborProductivityIncreasedValueAddedIncreasedRateofOperationReducedBreakdowns•Cost成本MoreEffectiveUseofManpowerReducedMaintenanceCostsReducedEnergyCosts•Quality品質ReducedDefectsinProcessReducedCustomerClaims•Morale士气IncreaseinImprovementIdeasImprovedCommunicationthroughsmallgroupmeetings•Delivery交付IncreasedScheduleAdherenceIncreasedStockTurns•Safety/Environment安全/環境ZeroAccidentsZeroPollutionBeltonConfidential‹#›OverviewofAutonomousMaintenance自主維護概述Objectives目的•Improvemachineandworkproductivity提高產能•Improveemployeemorale提供雇員士氣•Improveworksatisfaction提高工作滿意度•Reduceunplanneddowntime降低非計划停機時間•Reducespeedloss降低速度損耗BeltonConfidential‹#›OperationalRoles運作角色InTPMmaintenanceisaskingformanufacuturingassistance.在TPM中維修請求生產幫助InTPMmanufacturingisaskingformaintenanceassistance.在TPM中生產請求維修幫助Bothdepartmentsarethewheelsofthesamecar.兩個部門相當于同一輛車上的輪子Operator操作員Maintenance維修員BeltonConfidential‹#›ChangeAttitude態度改變Dramaticchangeinattitude在態度上的戲劇性變化Oldattitude老的態度itisnotheoperator‘sresponsibilitytoperformcleaningandinspection清洁和檢查不是員工的責任allequipmentwilleventuallygivefaultsandfailure所有設備終究會有毛病和故障allfaultsandfailuresofequipmentcanberectifiedbymaintenance所有毛病和故障都須維修員來處理Newattitude新的態度Weshareresponsibilityforcaringofourmachine,asiftheyareextensionsofourlimbsandarms我們要分擔責任來看護機器﹐把機器當作我們的四肢It'syourproblem!!AllequipmenthavefaultsandfailuresBeltonConfidential‹#›BenefitsofAtuonomousMaintenance自主維護的好處BenefitsofAutonomousMaintenanceinclude自主維護的好處ImproveProductivity提高生產力ImproveQuality改善品質ReducedCycleTime降低周期時間ReduceSpeedLoss降低速度損耗ReduceEquipmentMaintenanceCost降低設備維修成本Improveteamworkandcrossfunctionalrelationship加強團隊合作和相互關系ValueofAutonomousMaintenance自主維護的价值Changeofworkculturefrom“Icanonlyoperatethismachine”to“machineisapartofmyduty”改變工作文化,從“我是這台設備的操作員”到“設備是我職責的一部分”Equipmentproblemsareopportunitiesforimprovement設備的問題也就是改善的机會BeltonConfidential‹#›Training培訓Todevelopaknowledgeableoperator培養有見識的員工Howequipmentfunctions?設備怎么運作?Whatcommonproblemoccurs?什么樣的常見問題發生?Howtodetectproblemsthroughfivesenses/feeling?怎樣通過五官/感覺來發現問題?Thatthereissomething‘FUNNY’?有趣嗎?whyandhowthosesimpleproblemscanbeprevented?這些簡單的問題怎樣預防?Tomakemanufacturinganactivepartnerwithprocessengineeringandmaintenanceforimprovingoverallperformanceofmachines將生產部變成PE和ME的積极伙伴來改善機器的總效能BeltonConfidential‹#›HowtoachieveAutonomousMaintenance如何達到自主維護5SManagement5S管理VisualManagement目視管理StandardizedWork標准化作業Equipmentoperationskillenhancement提高設備操作技術Breakdownbarriers打破障礙Highlevelmaintenancemanagement高水平維護管理Ownershipresponsibility主人翁精神TransferofPMactivitiestooperator員工參与技術性的維護活動Allemployeesinvolved全員參与BeltonConfidential‹#›AutonomousMaintenanceforassemblyline裝配生產線自主維護裝配生產線的自主維護6大點步驟活動要點步驟活動要點第1點初期清掃清理一切不必要的徹底清除垃圾,污染,灰塵有用零件,工具,產品的標示第4點總點檢工具,器具,儀表總點檢計划檢查防錯系統的開發第2點操作整頓避免作風散布對策部件拿取容易的對策蹲,彎腰動作的對策零件FIFO(先進先出)改善第5點JIT意識零件供給,物料進出反饋零件工作台的高度和方向最佳化WIP控制,最适合庫存品質反饋系統產品搬運,人員走動的适當化第3點制訂基准清掃點檢標准的擬定作業標准的擬定人員配比員工多技能培訓表第6點標准化作業工序穩定作業標准与總點檢標准整合防止品質不良构筑柔性生產构筑標准生產系統BeltonConfidential‹#›ThekeyfocusofaLeanfactoryistoestablishaprocesssystemwhichisFast,Flexible&Predictable精益工厂的核心目的是建立一個快速的﹑靈活的和可預見的系統Allequipmentsetsdon‘tperformatasamefixedratesallthetime