生產(chǎn)部門如何推行TPM .PPT

1、1Total Productive MaintenanceManufacturing 生產(chǎn)部門2 ProcessCertificationTPMQCPCRoot Cause /CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinic ActivityTotal Productive Maintenance ACE Manufacturing Qualifying Level 3 程序驗證程序驗證全面性生產(chǎn)全面性生產(chǎn)維護維護質(zhì)量診斷程序質(zhì)量診斷程序圖表圖表根本原因

2、根本原因修正行動修正行動減少生產(chǎn)減少生產(chǎn)準備準備標準化標準化作業(yè)作業(yè)防誤措施防誤措施市場反饋市場反饋分析分析6S質(zhì)量診斷質(zhì)量診斷行動行動全面生產(chǎn)性維護 ACE 生產(chǎn)部門合格水平 4Total Productive Maintenance is an equipment management strategy that improves equipment efficiency.全面生產(chǎn)性維護是一種設(shè)備管理策略以提高設(shè)備效率。Or, in other words.Treating the equipment like it is your own!或者，換句話說.對待設(shè)備就象它是你自己的一樣！T

3、PM 全面生產(chǎn)性維護5TPM Key Concept TPM的重要概念 Left neglected. Equipment Breaks Down 如果不重視設(shè)備很快就會壞TPMs focus is to prevent problems before equipment breaks.TPM 的焦點是要在設(shè)備出故障以前以前防止問題出現(xiàn)。In the past, maintenance focusedon fixing equipment after it broke.過去，維護工作總是集中在設(shè)備壞了以后對其進行修理。6Total Productive Maintenance is a New

4、 Way of Working全面生產(chǎn)性維護是一種全新的工作方式全面生產(chǎn)性維護是一種全新的工作方式7Hidden Defects隱藏的問題隱藏的問題Failures故障故障Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw materials,surface damage, cracking, overheating, vibration, noise, and other abnormalities.磨損、松馳、泄露、灰塵、污垢、腐蝕變磨損、松馳、泄露、灰塵、污垢、腐蝕變形、

5、原材料粘黏、表面磨損、裂縫、過熱形、原材料粘黏、表面磨損、裂縫、過熱、震動、噪音及其它不正?，F(xiàn)象。、震動、噪音及其它不正?，F(xiàn)象。Tip of the Iceberg冰山的頂端8Typical Causes of Machine Breakdown 典型的機械故障原因Failure toadd oil.沒有加油Grit and chipsin revolvingor sliding parts旋轉(zhuǎn)或滑動零件中的砂礫和碎片Contaminationof sensors,contacts and Connectors傳感器、觸敏器、連接器污染Dirt and dust on cooling fan冷

6、卻風扇上有灰塵和污垢ComponentFailure組件失靈I wonder whatsgoing to fail next?我在想下面還會出什么我在想下面還會出什么問題呢？問題呢？9TPM Techniques TPM技術(shù)Normal operating Range正常操作范圍正常操作范圍Danger!危險！危險！ Simplify and Document TPM Activities. 簡化并記錄TPM行動 Use visual techniques to indicate whats right / whats wrong. 運用直觀技術(shù)來演示什么是 對的/什么是錯的。PM Compl

7、eted? 生產(chǎn)性維護完成了嗎？Pressure gage 壓力計Sight glass 視鏡Arrows for motor rotation and fluid circulation馬達旋轉(zhuǎn)和潤油指示箭頭markings for spare parts and fluids. 備用零件和潤滑油記號Making PM devices more accessible. 使生產(chǎn)性維護設(shè)備更容易獲得 Filters, fittings made more accessible 過濾器、各種裝置Transparent panels to facilitate inspection 明了易讀的儀表盤

8、便于檢查10TPM Benefits TPM的益處 Reduced maintenance costs 減少維護費用 Breakdown maintenance is 10 times more costly than planned maintenance 故障維修費用是有計劃進行維護費用的10倍以上 Enhanced safety 提高安全性 Find exposed wires, open belts, missing guards, loose hardware 發(fā)現(xiàn)暴露在外的電線、松開的安全帶、缺少防護、松開的部件 Reduced waste 減少浪費 Prevents loss o

9、f lubricant, compressed air 防止?jié)櫥?、壓縮空氣的浪費 Improved quality 提高品質(zhì) Equipment more capable of holding tolerance 設(shè)備抗性增強 Less down time, longer life縮短停工時間，壽命更長1112 TPM Qualifying ActivitiesACE Element Awareness TrainingLock Out/Tag Out awareness training available for all employees (with annual refresher)

10、Operators of high hazard equipment informed of machine specific hazardsAssessment of machine specific safeguarding (SP-008) issuesLock Out/Tag Out Equipment AvailableReview OnlyAction ItemsAssess all Equipment A, B & CImplement written Lock Out/Tag Out procedureWalk around safety check on 100% o

11、f A/B equipmentPM Schedule for 100% of A/B equipmentCleaning on 100% of A/B equipmentTrack downtime historyTop ten downtime equipment identified1212 項TPM 合格行動ACE 內(nèi)容認知培訓(xùn)鎖定/標識 認知培訓(xùn)，針對所有員工（每年的復(fù)習(xí)進修者）告知高危險設(shè)備操作員有關(guān)機器的詳細危險機器的特殊防護措施（SP-008）問題評估可用的鎖定/標識設(shè)備僅用于檢查行動內(nèi)容評估所有 A, B & C類設(shè)備完成寫好的鎖定/ 標識程序所有 A/B類設(shè)備的安全巡

12、查所有 A/B類設(shè)備的生產(chǎn)性維護進度表清潔所有A/B類設(shè)備追溯停工歷史確認的十大停工設(shè)備13PURPOSE of Lockout/Tagout鎖定鎖定/標識的目的標識的目的Lockout/Tagout Review:鎖定鎖定/標識檢查標識檢查14Lockout Device 鎖定設(shè)備A lock or other device that utilizes a positive means, to hold an energy isolating device in a safe position and thereby preventing the energizing of a machin

13、e or piece of equipment.一把鎖或其它設(shè)備，用于使電源設(shè)備隔離裝置處于一安全的狀態(tài)，以防止機器或設(shè)備的一部分帶電。Lockout/Tagout Review:鎖定鎖定/標識檢查標識檢查15Tagout Definition 標識的定義 The process of securely fastening a tag or prominent warning sign to indicate that both the energy isolating device and the equipment being controlled, be operated. 是將一標簽或

14、明顯的警告標志緊附于設(shè)備上 以表明不能不能對電源隔離設(shè)備及處于控制下的 設(shè)備進行操作。 The tag will also include the name of the person who locked out the equipment.該標簽應(yīng)有鎖定該裝置的 人的名字。Lockout/Tagout Review:鎖定鎖定/標識檢查標識檢查16NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.決不要從它人處接受鎖定設(shè)備的鑰匙。決不要從它人處接受鎖定設(shè)備的鑰匙。THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR

15、TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOCK OR TAG.唯唯有經(jīng)授權(quán)負責運用鎖或標簽的人員可以拿掉該鎖或標簽。有經(jīng)授權(quán)負責運用鎖或標簽的人員可以拿掉該鎖或標簽。Lockout/Tagout Review:鎖定鎖定/標識檢查標識檢查17ACTION ITEM 1: Assess All Equipment行動內(nèi)容行動內(nèi)容1：評估所有設(shè)備：評估所有設(shè)備 By “Equipment” we mean any machine that was a capital expense and has a depreciative value.

16、Or any machine that is important to your cell. 所謂“設(shè)備”是指任何花費了資金并會貶值的機器?；蛉魏螌δ愕牟块T重要的機器。We Categorize all Equipment based on how Unique and Critical it is to ensure we focus attention on the right equipment first. Pay special attention to bottleneck equipment.我們根據(jù)設(shè)備的獨特性和重要性對所有設(shè)備進行分類，以確保我們的注意力優(yōu)先放在正確的設(shè)備上。

17、對瓶頸設(shè)備給予特殊的關(guān)注。Equipment設(shè)備設(shè)備18 Critical equipment for which an alternate machine is not feasible, because:不能用其它設(shè)備替代的關(guān)鍵設(shè)備，因為： No alternate exists, or 無替代設(shè)備，或 The alternate is usually unavailable due to utilization, or 該替代設(shè)備通常正被使用而不能獲得，或 It would be too costly/time consuming to transition to the alterna

18、te 太貴/需花太多時間進行替換 Equipment for which it is relatively easy to find a replacement or alternate相對容易用其它設(shè)備替代的設(shè)備 Includes most off-the-shelf equipment 包括最常用的設(shè)備 Typically cost $2,500 費用低于$2,500 Standard spare parts (like drive motors) are available off-the-shelf 可獲得的常用標準備件（如驅(qū)動馬達） All other equipment/machi

19、nes所有其它設(shè)備/機器ACTION ITEM 1: Assess All Equipment (cont.)行動內(nèi)容行動內(nèi)容1：評估所有設(shè)備（待續(xù)）：評估所有設(shè)備（待續(xù)）19In addition to machine category, create a table listing all machines and additional categories, such as: 除了機器分類，還應(yīng)作一表格列出所有機器和附加類別，如：Year of manufacture產(chǎn)品的生產(chǎn)年份Type of machine? Condition? (Good / Fair / Poor)機器類型？狀

20、況？（好/一般/差）Does Operator PM process exists (Has a service card been created?)是否有操作員生產(chǎn)性維護程序（是否有服務(wù)卡？）Does Maintenance PM process exist (Does a written maintenance task list exist?)是否有維護生產(chǎn)性維護程序（是否有記錄的維護任務(wù)表？）Has the machine undergone initial cleaning?機器是否經(jīng)過最初的清潔？Has machine been assessed for safeguarding

21、 per SP008? (EH&S items)機器是否經(jīng)過安全裝置SP008評估？（EH&S項）ACTION ITEM 1: Assess All Equipment (cont.)行動內(nèi)容行動內(nèi)容1：評估所有設(shè)備（待續(xù)）：評估所有設(shè)備（待續(xù)）MACHININGSafety Plan - 2000AREA: 007MACHINE CATAGORYBRASS TAGYEARTYPE EQUIPGEN. COND. GOOD/FAIR/ POORB312488BridgeportGoodB300485HardingeGoodBE1507558Warren Spin PitPoor

22、BE6049187Shadow graphGoodBE7631291Balance controllerGoodB316890BostoGoodB261578BostoGoodB254875LapperGoodB328093OkumaGoodB319891Harrison man. latheGood20Possible Categories:可能的分類： Equipment which retains all of its original functions, accuracy and reliability. ：設(shè)備保持所有原來的功能，精確并可靠。 Equipment which has

23、 lost some of its original functions or accuracy. Its output normally meets the required specifications.：設(shè)備喪失了一些最初的功能或精確度。其產(chǎn)品符合要求的規(guī)范。 Equipment which is no longer accurate or reliable. In order to produce acceptable output, this equipment requires operator intervention well beyond the original level

24、. 設(shè)備不再精確或可靠。為了生產(chǎn)出可接受的產(chǎn)品，要求操作員對設(shè)備進行超出原有水平的干涉。ACTION ITEM 1: Assess All Equipment (cont.)行動內(nèi)容行動內(nèi)容1：評估所有設(shè)備（待續(xù)）：評估所有設(shè)備（待續(xù)）21ACTION ITEM 2: Write Machine-Specific Lockout ProceduresLockout procedures must be written and implemented for each machine General procedures are in effect for Sullair Procedures

25、need to be written jointly with facilities maintenance22行動內(nèi)容 2: 將特殊鎖定程序?qū)懺跈C器上鎖定程序必須寫在每臺機器上并予以執(zhí)行 一般程序適用于壽力公司 程序必須與設(shè)備維護 共同寫下來23 ACTION ITEM 3/4: Operator Walkaround and PM Schedule on 100% A/BOperator PM defined for 100% of Category A and B machines A book or sheet exists which defines the daily/weekly

26、/monthly Operator PM tasks Include safety equipment operation (guards, limit switches, etc.) in Operator PM.Operator PM conducted faithfully (1 month prior to audit) on all Equipment for which it is defined.Rev: BRevision Date: 3/ 25/98Operator Preventive Maintenance Service CardMachine: Okuma LC-30

27、, 4 Axis, BT # 3054Daily PM Tasks1. Check running sight.2. Check and fill Waylube: Vactra 2.3. Check tramp oil and scrounger. Empty tramp oil if required.4. Check and fill coolant: PML 9333.Weekly PM Tasks: Do Daily tasks and the following:1. Check and fill spindle lube: DTE 24.2. Check and fill air

28、 lubricator: DTE 24. (Shut off and drain air to fill)3. Check motor fan filter (Change if necessary): Cat. # 030058.4. Check and fill hydraulic tank: DTE 24.5. Check roll filter (Change if needed): Cat. # 027793.Monthly PM Tasks: Do all tasks on this sheet.1. Grease chuck fittings, 1 shot.2. Grease

29、1 fitting, 2 shots, both turrets.3. Clean air filter.4. Change air filter: Cat. # 021183.24 行動內(nèi)容 3/4: 操作員巡查和操作員巡查和 所有所有 A/B類設(shè)備的類設(shè)備的PM進度表進度表操作員PM定義為所有A、B類機器 應(yīng)有寫明了操作員每日/周/月的PM任務(wù)的書或表 包括安全設(shè)備（防護裝置、限定電閘等）操作員嚴格地按要求對所有設(shè)備進行生產(chǎn)性維護（在審查前一個月）Rev: BRevision Date: 3/ 25/98Operator Preventive Maintenance Service Car

30、dMachine: Okuma LC-30, 4 Axis, BT # 3054Daily PM Tasks1. Check running sight.2. Check and fill Waylube: Vactra 2.3. Check tramp oil and scrounger. Empty tramp oil if required.4. Check and fill coolant: PML 9333.Weekly PM Tasks: Do Daily tasks and the following:1. Check and fill spindle lube: DTE 24.

31、2. Check and fill air lubricator: DTE 24. (Shut off and drain air to fill)3. Check motor fan filter (Change if necessary): Cat. # 030058.4. Check and fill hydraulic tank: DTE 24.5. Check roll filter (Change if needed): Cat. # 027793.Monthly PM Tasks: Do all tasks on this sheet.1. Grease chuck fittin

32、gs, 1 shot.2. Grease 1 fitting, 2 shots, both turrets.3. Clean air filter.4. Change air filter: Cat. # 021183.25Make Operator PM effective:Use a “Visible at-a-glance” system (Such as a color-coded PM Status board) within the cell to indicate the actual status of “Operator PM” tasks. Must be easy to

33、understand No book or folder to read ACTION ITEM 3/4: Operator Walk around and PM Schedule on 100% A/B (cont.)AREA:_ - OPERATOR PM STATUS BOARDMonth:_Required PMsDateMachine NameBrass Tag #DailyWeeklyMonthly12345678910Daily = Task #1in PM LogsWeekly = Task #2 in PM Logs (to be done every Wednesday)M

34、onthly = Task #3 in PM Logs (to be performed every 2nd Wednesday of the month)Machine Not Operated or PM Not RequiredEquipment Breakdown26使操作員進行有效的生產(chǎn)性維護:使用一眼就能看見的系統(tǒng) (如使用顏色代碼PM狀態(tài)板) 在單元中表明“操作員PM”任務(wù)的實際狀態(tài) 必須容易理解 無需翻書或文件夾行動內(nèi)容 3/4: 操作員巡查和操作員巡查和 所有所有 A/B類設(shè)備的類設(shè)備的PM進度表進度表（待續(xù)）（待續(xù)）AREA:_ - OPERATOR PM STATUS B

35、OARDMonth:_Required PMsDateMachine NameBrass Tag #DailyWeeklyMonthly12345678910Daily = Task #1in PM LogsWeekly = Task #2 in PM Logs (to be done every Wednesday)Monthly = Task #3 in PM Logs (to be performed every 2nd Wednesday of the month)Machine Not Operated or PM Not RequiredEquipment Breakdown27C

36、osmetic Cleaning禁止化裝品禁止化裝品ACTION ITEM 5: Initial Inspect/Clean 100% A/B行動內(nèi)容 5：初步檢查/清潔所有A/B類設(shè)備28 Accessible components cleaned, inspected and repaired 可用的部件已清潔、檢查和修好 PM documentation is reviewed/updated PM文件已檢查/更新 Basic improvements are incorporated to improve maintainability and visual 基本的改進用于提高可維護性和形象 operating condition 操作環(huán)境How about that. I didnt even know there was a grease fitting here!那個怎么樣。我甚至不那個怎么樣。我甚至不知道這兒還有個油脂知道這兒還有個油脂裝置！裝置！ACTION ITEM 5: Initial Inspect/Cleaning 100% A/B