全面生產維護tpm培訓教材(更新版)

　　

【正文】 取樣到送至實驗室耗時3 2 分鐘機器Z 返修2 0 0 個工件由于機油線路泄漏機器D 僅能以每小時加工1 0 0 片產品的速度運行達不到1 2 5 片的標準 S C E N A R I O L O S S I D E N T I F I C A T I O N 1. M a c h i n e A o p e r a t i o n i s i n t e r r u p t e d b y a n e l e c t r i c a l p r o b l e m f o r 3 1 m i n u t e s 由于電氣故障機器 A 的運轉中斷 31 分鐘 2. A n i n p r o c e s s q u a l i t y c h e c k t a k e s 2 2 m i n u t e s 3. L o a d u n l o a d t i m e b e t w e e n w i d g e t s o n m a c h i n e B i s 4 m i n u t e s 機器 B 上的小部件 裝卸的時 間 為 4 分鐘 4. M a c h i n e X o p e r a t i o n i s i n t e r r u p t e d o f 8 m i n u t e s d u e t o a m e c h a n i c a l p r o b l e m 由于機械故障機器 X 運轉中斷 8 分鐘 5. C l e a n i n g t i m e o n m a c h i n e Z i s 4 7 m i n u t e s 機器 Z 的清潔時間為47 分鐘 6. J a m m e d p i e c e c a u s e s m a c h i n e C s t o p p a g e o f 3 m i n u t e s 7. M a c h i n e A c o m p l e t e s a l o a d a t 1 : 0 0 p m a n d b e g i n s a n o t h e r l o a d ( d i f f e r e n t p r o d u c t ) a t 2 : 2 7 p m 8. A s a m p l e i s t a k e n a n d t r a n s p o r t e d t o t h e l a b t a k i n g 3 2 m i n u t e s 9. 2 0 0 p i e c e s a r e r e p r o c e s s e d o n m a c h i n e Z 10. M a c h i n e D r u n s a t 1 0 0 p c / h r n o t 1 2 5 p c / h r d u e t o l e a k y o i l l i n e s 25 Total Productive Maintenance (TPM) Control Six Big Losses Identification Exercise S C E N A R I O L O S S I D E N T I F I C A T I O N 1. Mach i ne A op erat i on i s i nter rupt ed by an el ec t ri ca l prob l em f or 31 mi nu t es 2. A n i n proce ss qua l i t y ch ec k t ak es 22 mi nu t es 3. Lo ad un l oa d t i me be t w ee n w i dg ets on mach i ne B i s 4 m i nu t es 4. Mach i ne X op erat i on i s i nter rupt ed of 8 m i nu t es du e t o a mech an i ca l prob l em 5. C l ea ni ng t i me on mach i ne Z i s 47 mi nu t es 6. Ja mm ed pi ec e caus es mach i ne C st op pa ge of 3 m i nu t es 7. Mach i ne A co mpl etes a l oa d at 1:00 pm an d beg i ns an other l oa d (di f f eren t prod uc t ) at 2:27 pm 8 . A sa mpl e i s t ak en an d t ransp ort ed t o t he l ab t ak i ng 32 mi nu t es 9. 20 0 pi ec es are re proce sse d on mach i ne Z 10. Mach i ne D runs at 10 0 pc/ hr no t 12 5 pc/ hr du e t o l ea ky oi l l i ne s 26 Total Productive Maintenance (TPM) Control OEE的計算原理 承載時間 (LT) 設備運轉總的可利用時間 = 40 hrs 可用水平(AL) 運行水平 (OL) 質量水平 (QL) OEE 73% x 91% x 80% = 80% = 91% 質量原因 機器故障及輕微故障 , 行政事務 /非作業時間 機器 設置與調整 速度損失 機器空轉 返工及 報廢 40 = 73% 40 OEE = 53% AL HRS = 40 = hrs OL HRS = = hrs QL HRS = = hrs 27 Total Productive Maintenance (TPM) Control Calculating OEE Elements Loading Time (LT) Total Hours Available for Equipment Operation = 40 hrs Availability Level (AL) Operating Level (OL) Quality Level (QL) OEE 73% x 91% x 80% = 80% = 91% Quality Factors Breakdowns Minor Stops, and Admin. Setup Speed Losses Idling Rework and Scrap 40 = 73% 40 OEE = 53% AL HRS = 40 = hrs OL HRS = = hrs QL HRS = = hrs 28 Total Productive Maintenance (TPM) Control 世界級的 OEE性能水平 承載時間 (LT) 同步計劃運轉時間及生產性防護時間 可用水平 (AL) 運行水平 (OL) 質量水平 (QL) OEE 90% x 95% x 99% 質量 原因 機器故障及 輕微故障 , 行政事務 / 非作業時間 機器設置 與調整 速度 損失 機器 空轉 返工及 報廢 OEE = 85% 是世界級的性能水平 AL始終保持在 90%以上 OL維持在 95%以上 QL不低于 99% 29 Total Productive Maintenance (TPM) Control World Class OEE Performance Loading Time (LT) Operation Time and PM Time is scheduled synchronizing the two Availability Level (AL) Operating Level (OL) Quality Level (QL) OEE 90% x 95% x 99% Quality Factors Breakdowns Minor Stops, and Admin. Setup Speed Losses Idling Rework and Scrap OEE = 85% is World Class Performance The AL is consistently kept at or above 90% The OL is maintained at or above 95% The QL is at or above 99% 30 Total Productive Maintenance (TPM) Control 使設備恢復到可靠狀態 消除故障 開發 PM維護保養資料庫 消除缺陷 階段 I 階段 II 階段 III 階段 IV TPM 階段 31 Total Productive Maintenance (TPM) Control Return Equipment to Reliable Condition Eliminate Breakdowns Develop PM Information Database Eliminate Defects PHASE I PHASE II PHASE III PHASE IV TPM Phases 32 Total Productive Maintenance (TPM) Control 六大團隊活動 1. 通過小規模的小組活動來提高機器的正常運行時間 ,消除造成停工的主要根源 : ? 機器的啟動損失 ? 機器的故障損失 ? 待料損失和生產安排不當帶來的停機損失 2. 使操作員熟練地參與如潤滑 ,清潔 , 故障檢驗等基本的保養維護 . 33 Total Productive Maintenance (TPM) Control Six Team Activities 1. Use small group activities to improve machine uptime by eliminating the major sources of downtime. ? Startup Losses ? Breakdown Losses ? Material and Scheduling Losses 2. Involve the machine operators as well as skilled trades in basic preventative maintenance such as lubrication, cleaning, and inspection for defects. 34 Total Productive Maintenance (TPM) Control 六大團隊活動 (續上頁 ) 3. 使用諸如振動分析類的預測工具擯棄過去那種反應式的維護模式 4. 增強對設備的認知和了解以提高生產效能 ,減少停工時間 。 ? 建立設備故障資料庫 ? 收集并管理故障資料 ? 分析故障趨勢及形式 ? 定期展開和發布總結報告 ? 包括用于定期回顧之用的會議議程報告 85 Total Productive Maintenance (TPM) Control Equipment Failures ? Experts estimate that 60% of machine breakdowns associated with moving parts are due to lack of or improper lubrication practices. ? Establish an equipment failure database ? Gather and manage failure information ? Analyze for trends and patterns ? Develop and issue periodic summary reports ? Include reports as a meeting agenda for