精益生產(chǎn)之全面生產(chǎn)維護(hù)tpm(中英文版)3272276(編輯修改稿)

　

【文章內(nèi)容簡(jiǎn)介】 2. A n i n proces s qu al i t y che ck t ake s 22 mi nu t es 3. Lo ad un l oa d t i me be t w ee n w i dg et s on machi ne B i s 4 mi nu t es 4. Machi ne X op erat i on i s i nt err up t ed of 8 mi nu t es due t o a mecha ni cal probl em 5. C l ea ni ng t i me on machi ne Z i s 47 mi nu t es 6. Jammed pi ece cau ses machi ne C st op pa ge of 3 mi nu t es 7. Machi ne A pl et es a l oa d at 1: 00 pm an d be gi ns another l oa d ( di f f erent produ ct ) at 2: 27 pm 8 . A sampl e i s t ake n an d t r an spo r t ed t o t he l ab t aki ng 32 mi nu t es 9. 20 0 pi ece s are r e proces sed on machi ne Z 10. Machi ne D r un s 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(jì)算原理 承載時(shí)間 (LT) 設(shè)備運(yùn)轉(zhuǎn)總的可利用時(shí)間 = 40 hrs 可用水平(AL) 運(yùn)行水平 (OL) 質(zhì)量水平 (QL) OEE 73% x 91% x 80% = 80% = 91% 質(zhì)量原因 機(jī)器故障及輕微故障 , 行政事務(wù) /非作業(yè)時(shí)間 機(jī)器 設(shè)置與調(diào)整 速度損失 機(jī)器空轉(zhuǎn) 返工及 報(bào)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(jí)的 OEE性能水平 承載時(shí)間 (LT) 同步計(jì)劃運(yùn)轉(zhuǎn)時(shí)間及生產(chǎn)性防護(hù)時(shí)間 可用水平 (AL) 運(yùn)行水平 (OL) 質(zhì)量水平 (QL) OEE 90% x 95% x 99% 質(zhì)量 原因 機(jī)器故障及 輕微故障 , 行政事務(wù) / 非作業(yè)時(shí)間 機(jī)器設(shè)置 與調(diào)整 速度 損失 機(jī)器 空轉(zhuǎn) 返工及 報(bào)廢 OEE = 85% 是世界級(jí)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(shè)備恢復(fù)到可靠狀態(tài) 消除故障 開發(fā) PM維護(hù)保養(yǎng)資料庫(kù) 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(tuán)隊(duì)活動(dòng) 1. 通過小規(guī)模的小組活動(dòng)來提高機(jī)器的正常運(yùn)行時(shí)間 ,消除造成停工的主要根源 : ? 機(jī)器的啟動(dòng)損失 ? 機(jī)器的故障損失 ? 待料損失和生產(chǎn)安排不當(dāng)帶來的停機(jī)損失 2. 使操作員熟練地參與如潤(rùn)滑 ,清潔 , 故障檢驗(yàn)等基本的保養(yǎng)維護(hù) . 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(tuán)隊(duì)活動(dòng) (續(xù)上頁(yè) ) 3. 使用諸如振動(dòng)分析類的預(yù)測(cè)工具擯棄過去那種反應(yīng)式的維護(hù)模式 4. 增強(qiáng)對(duì)設(shè)備的認(rèn)知和了解以提高生產(chǎn)效能 ,減少停工時(shí)間 。 5. 使供應(yīng)管理和生產(chǎn)調(diào)度協(xié)同工作以確保持續(xù)穩(wěn)定的原材料供應(yīng) ,避免停機(jī)待料 。 6. 規(guī)劃人員配備以確保瓶頸設(shè)備處的滿員運(yùn)作 35 Total Productive Maintenance (TPM) Control Six Team Activities (Cont.) 3. Utilize predictive tools such as vibration analysis to move past reactive type maintenance 4. Increase awareness and knowledge of equipment to improve productivity and reduce downtime 5. Work with Supply Management and Production Control to insure a constant flow of raw material is available to preclude idling. 6. Develop manning schedules that insure that bottleneck machines are fully staffed 36 Total Productive Maintenance (TPM) Control TPM的益處 ? 提升操作員的參與感 ? 使設(shè)備恢復(fù)至更高的性能水平 ? 發(fā)現(xiàn)并消除早期的設(shè)備隱患 ? 減少總的制造成本 ? 減少浪費(fèi) ? 在保養(yǎng)設(shè)備方面樹立榮譽(yù)感 ? 促進(jìn)維護(hù)和生產(chǎn)部門之間的相互尊重與合作 37 Total Productive Maintenance (TPM) Control Benefits of TPM ? Promotes operator involvement ? Restores equipment to a higher performance level ? Uncover and eliminate premature equipment failures ? Reduce total manufacturing costs ? Reduces waste ? Builds a sense of pride in maintaining the equipment ? Promotes cooperation and respect between maintenance and production 38 Total Productive Maintenance (TPM) Control 職責(zé)范圍 ? 精益 6Sigma團(tuán)隊(duì) ? 倡導(dǎo)者 /發(fā)起人 ? TPM團(tuán)隊(duì) ? 操作員 ? 現(xiàn)場(chǎng)主管 ? 維護(hù)人員 39 Total Productive Maintenance (TPM) Control Areas of Responsibility ? Lean Six Sigma Team ? Champion/Sponsor ? TPM Team ? Operator ? Supervisor ? Maintenance 40 Total Productive Maintenance (TPM) Control 精益 6Sigma團(tuán)隊(duì)的任務(wù) ? 確定一個(gè) TPM項(xiàng)目的需求 ? 收集有關(guān)維護(hù)成本 ,延遲 (時(shí)延或操作延遲 ,設(shè)備利用率以及質(zhì)量問題的歷史數(shù)據(jù) ? 與操作員進(jìn)行深入溝通以了解他們的期望 41 Total Productive Maintenance (TPM) Control Lean Six Sigma Team Role ? Determine the need for a TPM Project ? Gather history of maintenance cost, delay, machine availability, and quality problems ? Interview Operators to get their prospective 42 Total Productive Maintenance (TPM) Control ? 現(xiàn)場(chǎng)活動(dòng) ? 組成 TPM團(tuán)隊(duì) ? 負(fù)責(zé)設(shè)備維護(hù)的人員 ? 操作員 ? 一線管理人員 ? 準(zhǔn)備必要的裝備 ? 幫助 TPM團(tuán)隊(duì)診斷異常 ? 協(xié)助跨功能培訓(xùn) ? 收集整理故障標(biāo)牌的拷貝并生成工作明細(xì)表 ? 提供人力資源方面的支持 精益 6Sigma團(tuán)隊(duì)的任務(wù) 43 Total Productive Maintenance (TPM) Control Lean Six Sigma Team Role ? On floor activities ? Assemble the TPM Team ? Mai