精益生产-全员生产维护TPM

泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20161TPMIntroduction全员生产维护介绍JustinTao陶建刚2016泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20162StabilizeBeforeYouImprove在你改进之前先稳定下来Whichplayerdidbetterinthisround?在这一轮中哪一个赢了？Whowilldobetterinalongrun?长远来看，谁会获胜？泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20163AvailabilityxReliability可用时间X可靠性• Theavailabilityofsurgicaltablelampisverylong(millionhours),butifitflashesoffinthemiddleofsurgeryitisnotplayingitsrole.手术室的无影灯的可用时间非常长（寿命在几百万小时），但是如果在手术过程中突然闪断，无影灯就失去了它的作用泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20164UnderMaintenance?正在维修?Remember:maintenancecomesfrommaintain,notrepair!记住：好的机器状态来自于维护，而不是维修！泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20165FailureDefinition故障的定义• Disfunctioningofanitemorinabilitytomeetastandardperformanceasprovided;某一方面的功能不全或者不稳定，没有办法满足正常的设备要求• Decreasethetotalorpartialcapacityofapart,componentormachinetoperformitsfunctionforaspecifictime;由于某些时候零件，部件或者机器的功能问题，造成总体或实际产能下降• Terminationoftheabilityofanitemtoperformitsrequiredfunction;根据正常的设备功能，某一方面不能已经不能实现Anequipmentmayberunningataspeedlessthanwhenitwasneworbeproducingproductswithdefects.机器在磨合期（新机器）或者带病工作的时候工作速度会比较低泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20166• Oilleakagesareconstant(solutionisthesawdust,sand);设备永远是漏油的（解决办法是锯屑，沙子）• Lubricationpointsaredriedorcloggedduetodirtiness;润滑点因为脏而堵塞了• Rotatingpartsandmovingsurfacesfullofchips,dust,dirtiness;旋转部件和接触面都是切屑和灰尘• Wiresandelectriccableshangeverywhereandsometimespeeledoff,itisnotknownwhichoneisonandwhichoneisoff;电线电缆挂得到处都是，有时候还剥落，根本不知道哪条是哪条• Wrongoperationandwearsinequipment’sparts;错误的操作和设备部件的磨损Themajorproblemiswheneveryoneinthecompanyisconvincedthatthisistheonlywaytoproduce最主要的问题是公司的每一个人都相信这是唯一的生产方式WhyMachinesBreakdown?为什么设备故障停机了？泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20167WhyFailuresOccurs?为什么会产生故障？• Failedduetopoordesignoftheequipment;因为设计的问题导致故障• Failedduetoincorrectoperationoftheequipment;不正确的操作导致故障• Failedduetopoormaintenanceofequipment;维护不良导致故障泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20168FailuresModel故障模式FailuresFrequencyoccurrence故障发生频率TimePrematureFailuresPeriod早期故障期RandomFailuresPeriod偶然故障期WearsFailuresPeriod损耗故障期1321RandomFailureFrequency随机故障率TheBathtubLine““浴盆曲线”2RisingFailureFrequency故障率上升3DeclineFailureFrequency故障率下降泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20169ObjectiveofMaintenance维护的目标Time“TheBathtubLine”“浴盆曲线”FailuresFrequencyoccurrence故障发生频率PrematureFailuresPeriod早期故障期RandomFailuresPeriod偶然故障期WearsFailuresPeriod损耗故障期泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.201610Equipments’LifeCycle设备的生命周期• Tosoftenthebathlinethemaintenancemustbeinvolvedthroughoutthelifecycleoftheequipments;要想平缓“浴盆曲线”，维护必须在设备的整个生命周期中发挥作用• Sinceitsprojectuntilthefinalstage;从项目的开始到最后报废IDÉIAOUPLANEJAMENTOIDEAORPLANNING计划PROJETODEENGENHARIAENGINEERINGPROJECT工程项目FABRICAÇÃOFABRICATION建造TRANSPORTEEINSTALAÇÃOTRANSPORTANDINSTALATION转运安装TESTEOUTRYOUTTESTORTRYOUT测试OPERAÇÃONAPRODUÇÃOOPERATIONALPROCESS运行加工MANUTENÇÃOMAINTENANCE维护REFORMAREFURBISH整修DESCARTEDISCARD报废泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.201611ForestFireAccident森林火灾泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.201612The Space Shu*le Challenger was destroyed 73 seconds a8er takeoff due on January 28, 1986. Only due to a faulty O-ring. It failed to seal one of the joints, allowing pressurized gas to reach the outside. This in turn caused the external tank to dump its payload of liquid hydrogen causing a massive explosion. The cost of replacing the Space Shu*le was $2 billion in 1986 ($4.5 billion in today's dollars). ChallengerExplosion-$5.5Billion挑战者爆炸泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.201613AssociatingMedicineandMaintenance医学和维护的关系DAILYCARE每日关注的BATHING洗澡BRUSHINGTEETH刷牙COMBINGHAIR洗梳头发TRIMMINGFINGERNAILS修剪指甲EATING饮食SURGERY手术REPAIR修理DAILYCARE每日关注的CLEANING清洁LUBRICATING润滑ORGANIZING整理INSPECTING检查OPERATING操作PREVENTIVEMEDICINE预防医学CURATIVEMEDICINE医学治疗PREVENTIVEMAINTENANCE预防维护CORRECTIVEMAINTENANCE纠正性维修泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.201614Totalnumberofbreakdowns故障总数PM预防维修AM自主维护Lackofthebasicconditions基本状况不良IncludingHumanerrors包括人工错误BetterUnderstandingoftheMaintenanceIssues维修问题的更好理解• Ingeneral,onethirdofbreakdowncomesfromlackofbasicconditions.总体上，三分之一的故障来源于基本状况不良• AnotheronethirdofthemcanbeavoidedifAMwithwellorganizedinspectionofnaturaldeterioration还有三分之一，如果很好地通过自主维护来检查自然衰退，就能够避免• TherestcanbedealbyPM其他的能通过预防性维护来解决泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.201615TPMHistoryTPM发展史1950 1stGener.TPMTPM第1阶段内容1971 1989 1997 1960 1970 1980 1990 2000 Manutenção Pós-Quebra 1957 - Manutenção por Melhoria TBM - Manutenção Baseada no Tempo CBM - Manutenção Baseada nas Condições As datas referem-se à divulgação oficial da Introdução no Japão