5.-Total-Productive-Maintenance

“TPM”TotalProductiveMaintenance全员生产维护HouseofLeanFlexibilityStandardizedWorkCellDesignFlowQualityatSource5SSystemVisualWasteEliminationSMEDTPMPull/KanbanKaizenValueStreamMappingContinuousImprovement精益屋灵活性标准化作业单元设计流源头质量5S体系可视度消除浪费SMEDTPM拉动式/看板改善价值流图持续改善TPM•ImprovingQuality,Productivity,andDeliveryThroughEquipmentReliability•通过设备可靠性改善质量、生产效率，以及交付效果AllAbout:在于：TPMKEYFOCALPOINTS关键焦点Requirestheinvolvementofallpeopleintheorganization.CustomerSatisfactionProductivityIncreaseOwner-operatorsFullPartnersTeamBuildingDedicatedpeople“LeanLeaders”需要组织中所有成员的参与客户满意度提高生产效率责任人-操作人员观念全面合作团队建设专门人员“精益领导者”TPMWhatisTPM?什么是TPM？TPMisamethodforcontinuouslyimprovingtheeffectivenessofproductionequipmentormanufacturingprocessesthroughtheinvolvementofallthepeopleintheorganization.TPM是通过组织内所有人员的参与，持续改进生产设备或制造流程效率的一种方法。KeyDifferencebetweenTPMandothermaintenanceimprovementinitiatives.TPMrequirestheinvolvementofallthepeopleintheorganization.TPM与其他维护改善措施之间的重要不同之处在于：TPM要求组织内所有人员的参与。TPM•Equipmentbreakdowns(unplanneddowntime)•Scrap/reworkcausedbypoorequipmentperformance•Reducedproductivityduetoequipment:runningatreducedspeedsreceivingunnecessaryadjustmentidlingorstoppageswhichrequiretheoperatorsattention•Equipmentstart-uplosseswhichoccurbeforetheprocessstabilizes•设备故障停工（计划外停工）•设备性能不佳造成的废品/返工•因为设备出现以下问题而造成的生产效率降低：运转速度降低进行不必要的调整需要操作人员加以注意的闲置或停机•流程稳定之前发生的设备启动事故*Toolforaccomplishing“CUSTOMERSATISFACTION”byworkingontheeliminationofcertainconditions.*通过消除特定的某些情况，实现“客户满意度”的方法。TPMRule#1TPM规则1TherearemanyshopfloorconcernswhichwilldevelopasaresultofimplementingTPM,includingmaintenancejobsecurity,additionaljobresponsibilitiesforoperators,jobclassifications,andunionsupport.Theseissuesmustberesolvedandcommunicatedbytopmanagementtoeveryonebeforetheimplementationcanstart.实施TPM时，要考虑许多车间问题，包括维护工作的安全性、操作人员的额外工作职责、工作分类，以及工会支持。这些问题必须在开始实施TPM之前得到解决，并由高层管理人员传达给所有人员。TPMRule#2TPM规则2ThesuccessofaTPMimplementationdependsonTPMbecomingadailypartofeveryone’sactivities.TPMmustdevelopintopartofthecompany’sculture.要实现TPM的成功实施，取决于TPM成为每个人日常活动的一部分。TPM必须发展成为公司文化的一部分。TPMResultsofTPMImplementation•ImprovedQuality.Equipmentintoprunningconditionproducespartswhichhavelessvariationinthem.•ImprovedProductivity.Eliminatingequipmentdowntime,stoppages,orreducedlinespeedsmakesusmoreproductive.•ImprovedDelivery.Customersatisfactionimprovesbecausecustomerscannowrelyonthescheduleddeliverydate.•ReducedInventory.Wenolongerhavetoproduce“justincasethere’sabreakdown”inventory.•ImprovedTeamMemberJobSatisfaction.Thereisnothingmorefrustratingforyourbestoperatorsthantolosecontrolof“theirmachine”whenitbreaksdown.Additionalfrustrationmaybuildasaresultofmissingacustomerdelivery,producingdefectivepartsthatmustbescrappedorreworked,orfinding”fillin”workasaresultoftheequipmentfailure.TPM实施TPM的成果•改进质量。设备以最佳性能运转，制造出的产品变异更小。•提高生产效率。消除设备故障、停工，或生产线速度降低的情况。•改善交付情况。客户满意度提高，因为客户现在可以信赖原定的交付日期。•降低库存水平。我们不再需要生产出“防止出现停工”的库存。•提高团队成员工作满意度。对于最优秀的操作人员而言，最让人生气的事情莫过于在发生机器故障时，自己只能束手无策。其他让人不快的事情还有因为设备故障影响客户交付，生产出必须报废或返工的缺陷零件，或是发现需要进行修补工作。TPMRule#3TPM规则3ToimplementTPM,apartnershipmustbedevelopedbetweenmanufacturing,maintenance,andengineeringwhichfostersanatmosphereofequipmentownership.EveryonemustworktogetherfortheTEAMtobesuccessful.为了实施TPM，制造、维护和工程部门必须开展合作，从而营造出一种对设备负责任的氛围。每个人都必须与他人合作，以实现团队的成功。TPM*Toolforimproving“PRODUCTIVITY”*提高“生产效率”的工具TPMstrivestoincreaseoperatorvalueaddedtimebyeliminatingtheequipmentconditionswhichreduceoperatorandequipmentproductivityandcreatewaste.TPMrecognizesthatthesewastescannotbeeliminatedwithouttheskillandparticipationoftheowner-operators.TPMmakesoperatorsfullpartnerswiththeMaintenanceDepartment.TPM力求通过消除会引起操作人员和设备的生产效率降低，造成浪费的设备问题，增加操作人员的增值时间。TPM确认只有在责任人-操作人员具备相关技能并参与其中的前提下，才能消除这些浪费。TPM让操作人员与维护部门开展全面合作。TPMRule#4TPM规则4ThekeytoaneffectivepreventativemaintenancecomponentwithintheTPMinitiativeisthemachineoperators.Upto75%ofbreakdownscanbedetectedandpreventedbywell-trainedoperators.在TPM举措中，实现有效的预防性维护的关键在于机器操作人员。有75%的故障停工本是可以由训练有素的操作人员加以发现和预防。TPMPrerequisitesforimplementingTPM实施TPM的先决条件TOPManagementCommitment.Projectcouldtakebetween3to8years,commitmentmustbetheretosupportandencouragetheorganizationalrolechanges,musthavethevisionand“gutwrenching”desiretomakethisimprovementoritwon’thappen.•5SImplementationwithinfacility.•TeamBuildingTraining.•Dedicatedpeople.“LeanLeaders”•Flexible,cross-trainableworkers.•最高管理层的承诺。项目耗时可能为三至八年，最高管理层必须做出承诺，从而支持和鼓励组织内成员完成角色转换，必须具备充分的远见和坚定的意愿才能真正获得改善结果。•在设施内实施5S体系。•团队建设培训。•专门人员。“精益领导者”•灵活的，接受过多领域培训的员工。TPM*5AvailableMaintenanceStrategies*5条可采用的维护策略1.Breakdown:Thisisthe“waituntilitbreaksandthenscramble”or“fire-fighting”strategy.Thistypeofmaintenanceisalsocalledreactivemaintenance.2.Preventative:Thisisperiodicorscheduledmaintenanceinvolvingoiling,greasing,adjusting,repairorreplacementofmachinecomponentsinordertopreventprematurewearandmajorproblems.Preventativemaintenanceincludesoverhaulswhichpreventequipmentperformancedeterioration.Preventativemaintenanceactivitiesareclassifiedunder“planneddowntime”.1.事后维护：这是指“当机器发生故障，影响生产才进行维修”或“见招拆招”的策略。这种维护策略也被称为被动式维护。2.预防性维护：这是指包括