Total-Productive-Maintainance

TerryGuoAug26,08TotalProductiveMaintenanceGroundRulesforEventSafetyfirst(usepersonalprotectiveequipment)安全第一Activeparticipationbyall有效参与Startandendontime准时Allelectronicgadgets(phones,pagers,etc)turnedto“off”or“silent”开会时关手机Computerstobeusedonlywheninstructed只有在需要的时候用电脑Keepanopenmindtochange持开放心态Don’tlet“perfect”getinthewayof“better”只要更好，不要最完美INTRODUCTIONWhatisTPM?Itisanapproachtomaximizetheeffectivityoftheplant’sequipmentintheareasofuptime,speed,andquality一种发挥设备效率最大化的方法Itisanapproachthatutilizestheexperienceandtalentoftheoperator,themaintenancetechnician,andengineeringasateam一种方式把操作人员，维修技术人员和工程师合而为一Itgoesbeyondsimplyrestoringandrepairingtheequipment.Itincludessustainingprocessesandcontinuousimprovement不仅仅是修复设备，更包含持续改进的文化Itimprovestheefficiencyofthosepeopleinvolvedinthesetup,operationandmaintenanceoftheequipment提高团队合作的效率INTRODUCTIONTPMisNOT“TotallyPaintedMachines”butrather“TakingPrideinourMachines”TPM的定义使设备的效能最佳关注设备的整个寿命周期，持续改进协调所有的部门包括所有的员工参与通过团队工作来完成Exercise:DiscussionOneparticipantfromeachgroupreportsanswersdiscussedtoclass10minutesInsmallgroups,discussandanswer:“Whataresomeoftheproblemswefaceinmaintainingequipment?”Selectonepersontorecordanswers.Discusspastequipmentmaintenanceexperiences.ObjectiveInstructionsTimetoCompleteDeliverableINTRODUCTIONApplytheTPMProcessontargetedequipmenttoimproveuptime,speedandqualityaswellasimplementaprocesstosustainandcontinuouslyimprovetheresults.GoalofTPMGoalOfTotalProductiveMaintenanceINTRODUCTIONMaintainabilityImprovementandMaintenanceAvoidance维护能力提高和预防性维护OEESustainandImproveOEE维持和提高AutonomousMaintenance自主维护RestoreDeterioration恢复劣化LossDataAnalysisandOEE缺失数据和OEEWhousesTPM?A$5MMinvestmentresultedina$16MMincreaseinprofitswhichcouldbetracedtoTPMimplementationBeganin1992–ledtoimprovementsinproductivityandcostsStartedin1986–productivityincreaseof50-80%Improvementsinmaintenancecosts,leadtimes,andOTDStartedin1991–increasedcapacity,costreductionsCompanyResults$200MM/yearsavingsattributabletoTPMEstablished“MaintenanceExcellenceRecognitionAward”INTRODUCTIONTraditionalvs.TPMINTRODUCTIONWhyImplementTPM?ImproveCustomerServiceImproveQualityImproveCostImproveEnvironmental,Health,andSafetyIMPROVEPROFITABILITY!INTRODUCTIONCanWeRespondtotheChallenge?INTRODUCTION•Demand=30,000Enclosures/month•1ShiftProductionL.T.=19.7daysProcessingTime=275seconds=5CutDOI=12”C/OTime=30’Uptime=99%Quality=99%5MachinesTPMshouldbetiedtoVSMKaizenBurstsI=1StampDOI=15”C/OTime=30’Uptime=99%Quality=98%=1BrakeFormDOI=20”C/OTime=120’Uptime=80%Quality=99%ShipAcmeSheetMetalCo.Ed’sElectricalSupplyMike’sMetalEnclosures(MME)III1XWeekDaily27,000Seconds1,500PiecesTaktTime=18seconds8.5days3.5days6.2days1.5days240sec15sec20secMonthlyP.O.(Faxed)DailyOrders(EDI)MRPSystemProductionControlWeeklyBuildSchedule(Paper)WeeklyBuildSchedule(Paper)WeeklyBuildSchedulePaperDailyShipSchedule(Paper)3,200Sheets5,250Pieces9,300Pieces2,300Enclosures1sheetyields4pieces30/60/90ForecastWeeklyFaxReduceManpowerTPM1pcFlowImproveDOIINTRODUCTIONTheTPMProcess1.Analyzedatatounderstandhistoricalperformance分析数据2.CorrectiveMaintenance,stabilizeequipmentconditionandrestoredeterioration修复设备，稳定运行3.AutonomousMaintenance,effectivelyutilizeoperatorstoactastheeyesandearsofthemechanics自主维护，有效利用操作人员成为设备故障的第一反应者4.InstallaprocesstosustainandimproveOverallEquipmentEffectivity建立维持和提高OEE的流程5.Improvemaintainabilityofequipment提高设备维修可维护能力6.Reducetheneedformaintenance减少设备的维修INTRODUCTIONThe“BigThree”IfyouhavenotchangedOperatingProcedureMaintenanceProcedureEquipmentDesignYouaredoomedtorepeathistory!INTRODUCTIONExercise:TPMCharterReviewMakeanymodificationstocharterasnecessary.30minutesAsateamreviewtheeventcharterandanswerthefollowingquestions:Whatisthebusinessneedforthisevent?Whatarethepre-selecteddepartments?Whataretheeventboundaries?Whoistheowner?Whatarethegoalsforthisevent?ReviewtheTPMCharterfortheeventagainstchartercriteriaObjectiveInstructionsTimetoCompleteDeliverableINTRODUCTIONLossDataAnalysisandOverallEquipmentEffectivenessDefineequipmenteffectiveness定义设备效率IdentifytheSixBigLosses找出六个缺失Completeananalysisofhistoricalperformance完成历史运行数据的分析IdentifycomponentsofOEE了解OEE的要素CalculateOEE计算OEEOBJECTIVESMaintainabilityImprovement&Maint.AvoidanceSustainandImproveOEEAutonomousMaintenanceRestoreDeteriorationLossDataAnalysisandOEEWhatisMaintenance’sProduct?MoreequipmentavailabilityMorerobustqualityoutputReducedinterruptionslongertimebetweenfailures(MTBF)ResponsivenesstocustomerdemandsSafetyEquipmentEffectivenessThegoaliscollaborationamongmaintenance,engineeringandoperationssomoretimecanbespentonthoseactivitieswhichaddvalueLOSSDATAANALYSISANDOEEDowntimeSpeedLossesQualityLossesBreakdowns设备停机Setupandadjustment换模和调整Idling,minorstoppages设备闲置，维护Reducespeed速度缺失Startupandyield设备启动和准备Defectsandrework返工和次品LossCategoriesSixBigLosses123Goal:ToreducelossesLOSSDATAANALYSISANDOEEAnalysisofHistoricalPerformanceThatIsIt?AprocessbywhichyoureviewthepastperformanceofaparticularmachineinthreeareasusingobjectivequantifiabledataMachinerelatedUptimeEasyQuali