精益生產之全面生產維護tpm(中英文版)1862272(編輯修改稿)

　

【文章內容簡介】 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(yè)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(yè)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(tài) 消除故障 開發(fā) PM維護保養(yǎng)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(guī)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(yǎng)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(xù)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 。 5. 使供應管理和生產調度協(xié)同工作以確保持續(xù)穩(wěn)定的原材料供應 ,避免停機待料 。 6. 規(guī)劃人員配備以確保瓶頸設備處的滿員運作 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 ? 使設備恢復至更高的性能水平 ? 發(fā)現(xiàn)并消除早期的設備隱患 ? 減少總的制造成本 ? 減少浪費 ? 在保養(yǎng)設備方面樹立榮譽感 ? 促進維護和生產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 職責范圍 ? 精益 6Sigma團隊 ? 倡導者 /發(fā)起人 ? TPM團隊 ? 操作員 ? 現(xiàn)場主管 ? 維護人員 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團隊的任務 ? 確定一個 TPM項目的需求 ? 收集有關維護成本 ,延遲 (時延或操作延遲 ,設備利用率以及質量問題的歷史數(shù)據 ? 與操作員進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)場活動 ? 組成 TPM團隊 ? 負責設備維護的人員 ? 操作員 ? 一線管理人員 ? 準備必要的裝備 ? 幫助 TPM團隊診斷異常 ? 協(xié)助跨功能培訓 ? 收集整理故障標牌的拷貝并生成工作明細表 ? 提供人力資源方面的支持 精益 6Sigma團隊的任務 43 Total Productive Maintenance (TPM) Control Lean Six Sigma Team Role ? On floor activities ? Assemble the TPM Team ? Mai