Total Productive Maintenance

Presentation on theme: "Total Productive Maintenance"— Presentation transcript:

1 Total Productive Maintenance
Manufacturing 生产部门

2 Total Productive Maintenance ACE Manufacturing Qualifying Level
6S TPM QCPC Market Feedback Analysis Set-Up Reduction Root Cause / Corrective Action Standard Work Process Certification Mistake Proofing Quality Clinic Activity

3 全面生产性维护 ACE 生产部门合格水平 6S 全面性生产 质量诊断程序 维护 图表 市场反馈 减少生产 分析 准备 根本原因 标准化
修正行动 标准化 作业 程序验证 防误措施 质量诊断 行动

4 TPM 全面生产性维护 Total Productive Maintenance is an equipment management strategy that improves equipment efficiency. 全面生产性维护是一种设备管理策略以提高设备效率。 Or, in other words... Treating the equipment like it is your own! 或者，换句话说……. 对待设备就象它是你自己的 一样！

5 TPM Key Concept TPM的重要概念
Left neglected... Equipment Breaks Down 如果不重视…设备很快就会坏 In the past, maintenance focused on fixing equipment after it broke. 过去，维护工作总是集中在设备坏了 以后对其进行修理。 TPM’s focus is to prevent problems before equipment breaks. TPM 的焦点是要在设备出故障以前防止问题出现。

6 Total Productive Maintenance is a New Way of Working 全面生产性维护是一种全新的工作方式
Old Attitude: 过去的态度： “I operate, you fix.” “我操作，你修理。” “I fix, you design.” “我处理，你设计。” “I design, you operate.” “我设计，你操作。” TPM Attitude: TPM态度： “We are all responsible for our equipment.” “我们所有人对我们的设备负责。”

7 Tip of the Iceberg 冰山的顶端
A failure is just the tip of the iceberg! 故障只是冰山的一个小尖！ Failures 故障 Hidden Defects 隐藏的问题 Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw materials,surface damage, cracking, overheating, vibration, noise, and other abnormalities. 磨损、松驰、泄露、灰尘、污垢、腐蚀变形、原材料粘黏、表面磨损、裂缝、过热、震动、噪音及其它不正常现象。

8 Typical Causes of Machine Breakdown 典型的机械故障原因
Contamination of sensors, contacts and Connectors 传感器、触敏器、 连接器污染 Grit and chips in revolving or sliding parts 旋转或滑动零件中的砂砾和碎片 I wonder what’s going to fail next? 我在想下面还会出什么 问题呢？ Component Failure 组件失灵 Ask: What are the 2 major causes of all equipment breakdowns? Answer: 1. Contamination 2. Lack of lubrication. Failure to add oil. 没有加油 Dirt and dust on cooling fan 冷却风扇上有 灰尘和污垢

9 TPM Techniques TPM技术 Simplify and Document TPM Activities. 简化并记录TPM行动
Use visual techniques to indicate what’s right / what’s wrong. 运用直观技术来演示什么是 对的/什么是错的。 PM Completed? 生产性维护完成了吗？ Pressure gage 压力计 Sight glass 视镜 Arrows for motor rotation and fluid circulation马达旋转和润油指示箭头 markings for spare parts and fluids. 备用零件和润滑油记号 Making PM devices more accessible. 使生产性维护设备更容易获得 Filters, fittings made more accessible 过滤器、各种装置 Transparent panels to facilitate inspection 明了易读的仪表盘便于检查 Normal operating Range 正常操作范围 Danger! 危险！

10 TPM Benefits TPM的益处 Reduced maintenance costs Enhanced safety 提高安全性
减少维护费用 Breakdown maintenance is 10 times more costly than planned maintenance 故障维修费用是有计划进行维护费用的10倍以上 Enhanced safety 提高安全性 Find exposed wires, open belts, missing guards, loose hardware 发现暴露在外的电线、松开的安全带、缺少防护、松开的部件 Reduced waste 减少浪费 Prevents loss of lubricant, compressed air 防止润滑油、压缩空气的浪费 Improved quality 提高品质 Equipment more capable of holding tolerance 设备抗性增强 Less down time, longer life缩短停工时间，寿命更长

11 12 TPM Qualifying Activities
ACE Element Awareness Training Lock Out/Tag Out awareness training available for all employees (with annual refresher) Operators of high hazard equipment informed of machine specific hazards Assessment of machine specific safeguarding (SP-008) issues Lock Out/Tag Out Equipment Available Review Only Action Items Assess all Equipment A, B & C Implement written Lock Out/Tag Out procedure Walk around safety check on 100% of A/B equipment PM Schedule for 100% of A/B equipment Cleaning on 100% of A/B equipment Track downtime history Top ten downtime equipment identified

12 12 项TPM 合格行动 仅用于检查 行动内容 ACE 内容认知培训 评估所有 A, B & C类设备
锁定/标识 认知培训，针对所有员工（每年的复习进修者） 告知高危险设备操作员有关机器的详细危险 机器的特殊防护措施（SP-008）问题评估 可用的锁定/标识设备 仅用于检查 行动内容 评估所有 A, B & C类设备 完成写好的锁定/ 标识程序 所有 A/B类设备的安全巡查 所有 A/B类设备的生产性维护进度表 清洁所有A/B类设备 追溯停工历史 确认的十大停工设备

13 Lockout/Tagout Review: 锁定/标识检查 PURPOSE of Lockout/Tagout 锁定/标识的目的
To prevent you or someone else from inadvertently turning a power source on and causing a potential injury or even death. 以防你或它人意外开动电源而造成可能的伤害甚至死亡

14 Lockout/Tagout Review:
锁定/标识检查 Lockout Device 锁定设备 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 machine or piece of equipment. 一把锁或其它设备，用于使电源设备隔离装置处于一安全的状态，以防止机器或设备的一部分带电。

15 Tagout Definition 标识的定义
Lockout/Tagout Review: 锁定/标识检查 Tagout Definition 标识的定义 The process of securely fastening a tag or prominent warning sign to indicate that both the energy isolating device and the equipment being controlled, must not be operated. 是将一标签或明显的警告标志紧附于设备上 以表明不能对电源隔离设备及处于控制下的 设备进行操作。 The tag will also include the name of the person who locked out the equipment. 该标签应有锁定该装置的 人的名字。

16 Lockout/Tagout Review:
锁定/标识检查 WARNING 警告 NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE. 决不要从它人处接受锁定设备的钥匙。 THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOCK OR TAG. 唯有经授权负责运用锁或标签的人员可以拿掉该锁或标签。

17 ACTION ITEM 1: Assess All Equipment 行动内容1：评估所有设备
By “Equipment” we mean any machine that was a capital expense and has a depreciative value. Or any machine that is important to your cell. 所谓“设备”是指任何花费了资金并会贬值的机器。或任何对你的部门重要的机器。 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. 我们根据设备的独特性和重要性对所有设备进行分类，以确保我们的注意力优先放在正确的设备上。对瓶颈设备给予特殊的关注。 Equipment 设备 For the purpose of ACE, only machines with Brass Tags are considered “Equipment”

18 ACTION ITEM 1: Assess All Equipment (cont.) 行动内容1：评估所有设备（待续）
Category A: Critical equipment for which an alternate machine is not feasible, because: A类：不能用其它设备替代的关键设备，因为： No alternate exists, or 无替代设备，或 The alternate is usually unavailable due to utilization, or 该替代设备通常正被使用而不能获得，或 It would be too costly/time consuming to transition to the alternate 太贵/需花太多时间进行替换 Category C: Equipment for which it is relatively easy to find a replacement or alternate C类：相对容易用其它设备替代的设备 Includes most off-the-shelf equipment 包括最常用的设备 Typically cost < $2,500 费用低于$2,500 Standard spare parts (like drive motors) are available off-the-shelf 可获得的常用标准备件（如驱动马达） Category B: All other equipment/machines B类：所有其它设备/机器

19 ACTION ITEM 1: Assess All Equipment (cont.) 行动内容1：评估所有设备（待续）
In addition to machine category, create a table listing all machines and additional categories, such as: 除了机器分类，还应作一表格列出所有机器和附加类别，如： Year of manufacture 产品的生产年份 Type of machine? Condition? (Good / Fair / Poor) 机器类型？状况？（好/一般/差） Does Operator PM process exists (Has a service card been created?) 是否有操作员生产性维护程序（是否有服务卡？） Does Maintenance PM process exist (Does a written maintenance task list exist?) 是否有维护生产性维护程序（是否有记录的维护任务表？） Has the machine undergone initial cleaning? 机器是否经过最初的清洁？ Has machine been assessed for safeguarding per SP008? (EH&S items) 机器是否经过安全装置SP008评估？（EH&S项）

20 ACTION ITEM 1: Assess All Equipment (cont.) 行动内容1：评估所有设备（待续）
Possible Categories: 可能的分类： Good: Equipment which retains all of it’s original functions, accuracy and reliability. 好：设备保持所有原来的功能，精确并可靠。 Average: Equipment which has lost some of it’s original functions or accuracy. It’s output normally meets the required specifications. 一般：设备丧失了一些最初的功能或精确度。其产品符合要求的规范。 Poor: Equipment which is no longer accurate or reliable. In order to produce acceptable output, this equipment requires operator intervention well beyond the original level. 差：设备不再精确或可靠。为了生产出可接受的产品，要求操作员对设备进行超出原有水平的干涉。

21 ACTION ITEM 2: Write Machine-Specific Lockout Procedures
must be written and implemented for each machine General procedures are in effect for Sullair Procedures need to be written jointly with facilities maintenance

22 行动内容 2: 将特殊锁定程序写在机器上 锁定程序必须写在每台 机器上并予以执行 一般程序适用于寿力公司 程序必须与设备维护 共同写下来

23 ACTION ITEM 3/4: Operator Walkaround and PM Schedule on 100% A/B
Operator PM defined for 100% of Category A and B machines A book or sheet exists which defines the daily/weekly/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: B Revision Date: 3/ 25/98 Operator Preventive Maintenance Service Card Machine: Okuma LC-30, 4 Axis, BT # 3054 Daily PM Tasks 1. 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: Check and fill spindle lube: DTE 24. Check and fill air lubricator: DTE 24. (Shut off and drain air to fill) Check motor fan filter (Change if necessary): Cat. # Check and fill hydraulic tank: DTE 24. 5. Check roll filter (Change if needed): Cat. # Monthly PM Tasks: all tasks on this sheet. Grease chuck fittings, 1 shot. Grease 1 fitting, 2 shots, both turrets. Clean air filter. Change air filter: Cat. #

24 Operator Preventive Maintenance Service Card
行动内容 3/4: 操作员巡查和 所有 A/B类设备的PM进度表 操作员PM定义为所有A、B类机器 应有写明了操作员每日/周/月的PM任务的书或表 包括安全设备（防护装置、限定电闸等） 操作员严格地按要求对所有设备进行生产性维护（在审查前一个月） Rev: B Revision Date: 3/ 25/98 Operator Preventive Maintenance Service Card Machine: Okuma LC-30, 4 Axis, BT # 3054 Daily PM Tasks 1. 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: Check and fill spindle lube: DTE 24. Check and fill air lubricator: DTE 24. (Shut off and drain air to fill) Check motor fan filter (Change if necessary): Cat. # Check and fill hydraulic tank: DTE 24. 5. Check roll filter (Change if needed): Cat. # Monthly PM Tasks: all tasks on this sheet. Grease chuck fittings, 1 shot. Grease 1 fitting, 2 shots, both turrets. Clean air filter. Change air filter: Cat. #

25 ACTION ITEM 3/4: Operator Walk around and. PM Schedule on 100% A/B
ACTION ITEM 3/4: Operator Walk around and PM Schedule on 100% A/B (cont.) Make 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 understand No book or folder to read

26 行动内容 3/4: 操作员巡查和 所有 A/B类设备的PM进度表（待续）
使操作员进行有效的生产性维护: 使用一眼就能看见的系统 (如使用颜色代码PM状态板) 在单元中表明“操作员PM”任务的实际状态 必须容易理解 无需翻书或文件夹

27 ACTION ITEM 5: Initial Inspect/Clean 100% A/B 行动内容 5：初步检查/清洁所有A/B类设备
You clean to improve a machine’s performance - not its appearance 清洁是为提高机器的性能- 而不是外表 Clean to Inspect 清洁以检查 Inspect to Detect 检查以发现 Detect to Correct 发现以改正 Cosmetic Cleaning 禁止化装品 You get a better looking piece of equipment as a benefit but not as the only objective 你可以使机器看起来更漂亮，但这不是唯一的目的

28 How about that. I didn’t even know there was a grease fitting here!
ACTION ITEM 5: Initial Inspect/Cleaning 100% A/B (Cont.) 行动内容 5：初步检查/清洁所有A/B类设备（待续） Accessible components cleaned, inspected and repaired 可用的部件已清洁、检查和修好 PM documentation is reviewed/updated PM文件已检查/更新 Basic improvements are incorporated to improve maintainability and visual 基本的改进用于提高可维护性和形象 operating condition 操作环境 How about that. I didn’t even know there was a grease fitting here! 那个怎么样。我甚至不 知道这儿还有个油脂 装置！

29 ACTION ITEM 6: Track Downtime History 行动内容 6：追溯停工历史记录
Maintenance Downtime is the time a machine is down for maintenance purposes 停工维护是指一台机器停工以便维护 的时期 Unplanned 非计划的 Breakdowns and Repairs 停工并维修 Planned 计划内的 Operator PM 操作员PM Maintenance PM 维护PM Maintenance Downtime Goal 停工维护目标 Reduce Breakdowns and Repairs 减少停工和维修

30 ACTION ITEM 7: Top Ten Downtime 行动内容 7：十大停工设备
Use downtime tracking results to determine the top ten downtime equipment. 根据停工追溯结果来决定 十大停工设备 Pareto Chart Pareto 图表

31 What is next? 下一步是什么？ Complete TPM training of your work group
by March 7, 2001 2001年3月7日前你的工作组应 完成TPM培训 Before the end of February, look for a groupwise announcement of a “Driver’s” Meeting to discuss the necessary resources and logistics for completing qualifying TPM activities 在2月底以前，宣布召开“领导层”会议， 讨论必要的资源和后勤以帮助完成 取得合格资格的TPM行动

32 我们希望公司尊敬那些设计、建造并维持不会坏 的东西的人们，而不是那些修理会坏的东西的人们。
Summary 小结 We want a company that reveres people who design, build and maintain things that never break, rather than people who fix things that break. George David UTC Chairman and CEO 我们希望公司尊敬那些设计、建造并维持不会坏 的东西的人们，而不是那些修理会坏的东西的人们。

33 Total Productive Maintenance 全面生产性维护
Manufacturing 生产部