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1、ControlControl精益生产之全面生产维护TPM中英文版 Still waters run deep.流静水深流静水深,人静心深人静心深 Where there is life,there is hope。有生命必有希望。有生命必有希望MeasureMeasureAnalyzeAnalyzeControlControlImproveImproveLean Six SigmaLean Six SigmaTotal Productive Maintenance(TPM)uTPMuTPM Team OrganizationuOverall Equipment Effectiveness uT
2、PM PhasesRD011202ControlControl精益6 过程改善流程分析分析分析分析控制控制控制控制改进改进改进改进定义定义选定题目列出客户从顾客之声中列出关建需求定出项目焦点和重要指标完成 PDF测量测量绘制业务流程图绘制价值流程图制定数据收集计划测量系统分析收集数据过程能力分析分析分析提出关键因子区分关键因子验证关键因子评枯每个关键因子对结果的影响量化机会根本原因排序寻找根本原因针对关键因子改进改进关键因子确认发掘潜在的解决方法选择方案优化方案实行方案控制控制过程变革和控制制定控制计划计算最终财务过程指标项目过渡给未来项目管理者项目鉴 别转化机会测量测量测量测量定义定义定义定
3、义项目编号工具项目定义表净现值分析内部回报率分析折算现金流分析 PIP管理过程RACIQuad 表过程图价值分析脑力风暴投票归类法柏拉图因果图/鱼骨图FMEA查检表运行图控制图量具 R&RCp&Cpk供应链加速器分析多变动图i盒状图交互作用图回归分析ANOVAC&E 矩阵图FMEA脑力风暴拉系统减少设置TPM流程图标杆管理亲和图DOE 假设检验力场分析图树状图甘特图查检表运行图柱状图散布图控制图柏拉图互动回顾愚巧法Revised 1-12-023Total Productive Maintenance(TPM)ControlControlLean Six Sigma Improvement P
4、rocess Road MapAnalyzeAnalyzeControlControlImproveImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem Ana
5、lysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelec
6、t SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureMeasureDefineDefineProject ID ToolsProject Definition FormNet Present
7、Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp&CpkSupplyChainAccelerator AnalysisM
8、ulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-Yo
9、keRevised 1-12-024Total Productive Maintenance(TPM)ControlControl课程目的u学习一种方法以便:n将作业流程中的起作用的所有生产要素整合为一个单一综合的衡量值（OEE）;n消除导致设备故障的因素;n使设备的养护清洁更易达成;n用预测性保养作为一种检测工具;n实施维护审查5Total Productive Maintenance(TPM)ControlControlLearning ObjectivesuLearn a method to:nIntegrate operational productivity factors appl
10、icable in process industries in a single comprehensive measurementnEliminate factors contributing to equipment failurenImprove accessibility for cleaning and maintaining equipmentnUse predictive maintenance as a diagnostic toolnImplement maintenance audits6Total Productive Maintenance(TPM)ControlCon
11、trol个人学习意义u流程作业和保养最优化u一种替代传统的在故障发生时检测并修复的方法;u一种源头监控和校正的先发系统;u一种基于对影响过程性能的主要因素其因果系统的理解工作策略;7Total Productive Maintenance(TPM)ControlControlWhats in It for Me?uOptimized process operations and maintenanceuA method to replace the traditional approach of detecting and correcting faulty conditions as the
12、y occuruA proactive system which monitors and corrects causesuAn operations strategy based on understanding the cause and effect system affecting the major contributors to process performance8Total Productive Maintenance(TPM)ControlControl全面生产维护(TPM)定义:u一种用于监控操作,设备保养,消除计划外停机,和提高作业与保养协调程度的常识性方法。9Tota
13、l Productive Maintenance(TPM)ControlControlTotal Productive Maintenance(TPM)TPM DefinitionuA common sense approach to monitor operations,maintain equipment,eliminate unscheduled downtime,and improve the level of cooperation between Operations and Maintenance.10Total Productive Maintenance(TPM)Contro
14、lControlTPMu通过实施预防实现设备零故障和零缺陷;u预防工作将立足于以下方面:n维持正常的生产条件n及早发现异常n快速反应11Total Productive Maintenance(TPM)ControlControlTPMuAchieve zero equipment breakdowns and zero defects through preventionuEstablish prevention bynMaintaining normal conditionsnEarly detection of abnormalitiesnQuick response12Total Pr
15、oductive Maintenance(TPM)ControlControl传统的反应式维护 维修部门“我们只管修理”n执行所有的维修作业n往往是一旦设备发生故障充当救火员的角色;n负责定购和保管所有的工具,备件等物资;n实施定期检修 生产部门 ”我们只管使用“n通常不作任何维护活动n一旦设备出现故障就与维修部门联系n维修作业中只能停工;n一直用到坏了为止13Total Productive Maintenance(TPM)ControlControlTraditional Approach“Re-Active Maintenance”Maintenance“WE FIX”nPerform
16、all maintenance activitiesnPerform“Fire Fighting”maintenance when a machine breakdown occursnOrder and administer all tooling,supplies,etc.nPerform Preventive MaintenanceManufacturing“WE OPERATE”nGenerally does not perform any maintenance activitiesnContacts maintenance when a machine breakdown occu
17、rsnInactive during maintenance activitiesn“Run it till it breaks”14Total Productive Maintenance(TPM)ControlControl主要概念定期保养是一种基于时间长短或使用状况对设备进行检修的方法.在指定时间或在使用空档间对设备实施检修作业以防止设备发生故障.n定期保养计划预测性保养是一种基于设备状态的维护方法.根据可视信号或检测技术的情况来实施保养以防止设备发生故障.n振动分析n激光探测n超声波检测n发电机测试n热感应n油况分析预测性保养预测性保养预测性保养预测性保养定期保养定期保养定期保养定期保
18、养15Total Productive Maintenance(TPM)ControlControlKey DefinitionsPreventive Maintenance is a time or usage based method of maintaining equipment.Maintenance activities are performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occurring.nPM Schedules
19、Predictive Maintenance is a situation based method of maintaining equipment.Maintenance activities are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring.nVibration AnalysisnLaser MeasuringnUltrasoundnGenerator TestingnThermography
20、nOil AnalysisPredictive MaintenancePredictive MaintenancePreventive MaintenancePreventive Maintenance16Total Productive Maintenance(TPM)ControlControl现状分析和团队组织u评估当前的操作条件:n机器利用率,生产率等;n维修费用(配件和人工)n对实现TPM的各项工作进行优先次序u评估潜在TPM倡导者及团队成员的实力u挑选TPM倡导者及团队成员n建立初始的实施专门小组n确定团队目标17Total Productive Maintenance(TPM)C
21、ontrolControlPresent State Analysisand Team OrganizationuAssess Current Operating ConditionsnMachine utilization,productivity,etc.nMaintenance repair costs(parts and labor)nPrioritize order of TPM effortsuAssess capabilities of potential TPM Champions and Team MembersuSelect TPM Champion and Team Me
22、mbersnEstablish initial kick-off workshopnEstablish team goal18Total Productive Maintenance(TPM)ControlControl典型的设备评价指标u利用率:设备实际运转时间与总的可利用时间的比率;n=实际运行时间/可运行时间u效率:实际产量与标准产量的比率n=(实际产量/小时)/(标准产量/小时)u产出:用一特定时间段的产量来衡量n=磅/小时,件数/小时19Total Productive Maintenance(TPM)ControlControlTypical Operational Process
23、 MeasurementsuUtilization:The ratio of equipment actual operating time to the total available operating timen=Actual Operating Time/Available TimeuEfficiency:The ratio of actual product produced to a standardn=(Actual Parts/Hour)/(Standard Part/Hour)uOutput:Measure of output over a specified time pe
24、riodn=lbs/hr,pieces/hr20Total Productive Maintenance(TPM)ControlControl设备综合利用率OEEu设备综合利用率（OEE）是衡量一台设备按计划速度生产出合格产品的时间占全部时间的百分比.21Total Productive Maintenance(TPM)ControlControlOverall Equipment EffectivenessuOverall Equipment Effectiveness(OEE)is the measure of the percent of time a piece of equipmen
25、t is producing quality product at the designed rate.22Total Productive Maintenance(TPM)ControlControlOEE分解:六大浪费故障及轻微故障故障及轻微故障使设备中断运行的时间超过10分钟的故障或者中断时间少于10分钟的轻微故障.设置时间浪费设置时间浪费任何与设备调整,装配,清洁相关的作业.机器空转浪费机器空转浪费设备在运转却没有用来生产产品所耗用的时间.速度浪费速度浪费由于设备或产品的异常造成设备以低于标准速度或所设定的速度运转.品质原因浪费品质原因浪费为确保设备产出品的品质而采取相关的作业(过程中
26、检查).返工浪费返工浪费用于返修产品或生产出报废产品所耗用的时间.可用水平可用水平可用水平可用水平(AL)AL)运行水平运行水平运行水平运行水平(OL)OL)质量水平质量水平质量水平质量水平(QL)QL)23Total Productive Maintenance(TPM)ControlControlOEE Breakdown:The Six Big LossesBreakdowns and Minor StoppagesMalfunctions causing equipment to stop processing greater than 10 minutes(breakdowns)or
27、 less than 10 minutes(minor stoppages)SetupAny activity related to equipment changeover,setup,or cleaning.IdlingTime equipment is running but not producing product.Speed LossesEquipment operating at less than standard or design speed due to equipment/product abnormalityQuality FactorsActivities rela
28、ted to ensuring the quality of the product produced on the equipment(in-process checks).Rework LossesThe time taken to re-process product or time take to produce un-usable product.Availability Level(AL)Availability Level(AL)Operating Level(OL)Operating Level(OL)Quality Level(QL)Quality Level(QL)24To
29、tal Productive Maintenance(TPM)ControlControl六大浪费的识别练习25Total Productive Maintenance(TPM)ControlControlSix Big Losses Identification Exercise26Total Productive Maintenance(TPM)ControlControlOEE的计算原理承载时间(LT)设备运转总的可利用时间=40 hrs可用水平(AL)运行水平(OL)质量水平(QL)OEE73%x 91%x 80%26.3-3.1-2.1=80%26.3 28.9-1.5-1.1=91
30、%28.9质量原因机器故障及轻微故障,行政事务/非作业时间机器设置与调整速度损失机器空转返工及报废 40-3.1-3.8-4.2=73%40OEE=53%AL HRS=40-3.1-3.8-4.2=28.9 hrsOL HRS=28.9-3.1-1.1=26.3 hrsQL HRS=26.3-3.1-2.1=21.1 hrs27Total Productive Maintenance(TPM)ControlControlCalculating OEE ElementsLoading Time(LT)Total Hours Available for Equipment Operation=40
31、 hrsAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE73%x 91%x 80%26.3-3.1-2.1=80%26.3 28.9-1.5-1.1=91%28.9QualityFactorsBreakdownsMinor Stops,and Admin.SetupSpeed LossesIdlingRework andScrap 40-3.1-3.8-4.2=73%40OEE=53%AL HRS=40-3.1-3.8-4.2=28.9 hrsOL HRS=28.9-3.1-1.1=26.3 hrsQL HRS=26.3-3.
32、1-2.1=21.1 hrs28Total Productive Maintenance(TPM)ControlControl世界级的OEE性能水平承载时间承载时间(LT)同步计划运转时间及生产性防护时间同步计划运转时间及生产性防护时间可用水平可用水平(AL)运行水平运行水平(OL)质量水平质量水平(QL)OEE90%x 95%x 99%质量原因机器故障及轻微故障,行政事务/非作业时间机器设置与调整速度损失机器空转返工及报废OEE=85%是世界级的性能水平AL始终保持在始终保持在 90%以上以上OL维持在维持在 95%以上以上QL不低于不低于 99%29Total Productive Mai
33、ntenance(TPM)ControlControlWorld Class OEE PerformanceLoading Time(LT)Operation Time and PM Time is scheduled synchronizing the twoAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE90%x 95%x 99%QualityFactorsBreakdownsMinor Stops,and Admin.SetupSpeed LossesIdlingReworkand ScrapOEE=85%is Worl
34、d Class PerformanceThe AL is consistently kept at or above 90%The OL is maintained at or above 95%The QL is at or above 99%30Total Productive Maintenance(TPM)ControlControl使设备恢复到可靠状态使设备恢复到可靠状态使设备恢复到可靠状态使设备恢复到可靠状态消除故障消除故障消除故障消除故障开发开发开发开发PMPM维护保养资料库维护保养资料库维护保养资料库维护保养资料库消除缺陷消除缺陷消除缺陷消除缺陷阶段阶段 I阶段阶段 II阶段阶
35、段 III阶段阶段 IVTPM 阶段31Total Productive Maintenance(TPM)ControlControlReturn EquipmentReturn Equipmentto Reliable Conditionto Reliable ConditionEliminateEliminateBreakdownsBreakdownsDevelop PMDevelop PMInformation DatabaseInformation DatabaseEliminateEliminateDefectsDefectsPHASE IPHASE IIPHASE IIIPHASE
36、 IVTPM Phases32Total Productive Maintenance(TPM)ControlControl六大团队活动1.通过小规模的小组活动来提高机器的正常运行时间,消除造成停工的主要根源:n机器的启动损失n机器的故障损失n待料损失和生产安排不当带来的停机损失2.使操作员熟练地参与如润滑,清洁,故障检验等基本的保养维护.33Total Productive Maintenance(TPM)ControlControlSix Team Activities1.Use small group activities to improve machine uptime by eli
37、minating the major sources of downtime.nStartup LossesnBreakdown LossesnMaterial and Scheduling Losses2.Involve the machine operators as well as skilled trades in basic preventative maintenance such as lubrication,cleaning,and inspection for defects.34Total Productive Maintenance(TPM)ControlControl六
38、大团队活动(续上页)3.使用诸如振动分析类的预测工具摈弃过去那种反应式的维护模式4.增强对设备的认知和了解以提高生产效能,减少停工时间;5.使供应管理和生产调度协同工作以确保持续稳定的原材料供应,避免停机待料;6.规划人员配备以确保瓶颈设备处的满员运作35Total Productive Maintenance(TPM)ControlControlSix Team Activities(Cont.)3.Utilize predictive tools such as vibration analysis to move past reactive type maintenance4.Incre
39、ase awareness and knowledge of equipment to improve productivity and reduce downtime5.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 staffed36Total
40、 Productive Maintenance(TPM)ControlControlTPM的益处u提升操作员的参与感u使设备恢复至更高的性能水平u发现并消除早期的设备隐患u减少总的制造成本u减少浪费 u在保养设备方面树立荣誉感u促进维护和生产部门之间的相互尊重与合作 37Total Productive Maintenance(TPM)ControlControlBenefits of TPMuPromotes operator involvementuRestores equipment to a higher performance leveluUncover and eliminate
41、premature equipment failuresuReduce total manufacturing costsuReduces waste uBuilds a sense of pride in maintaining the equipmentuPromotes cooperation and respect between maintenance and production 38Total Productive Maintenance(TPM)ControlControl职责范围u精益6Sigma团队u倡导者/发起人uTPM团队n操作员n现场主管n维护人员39Total Pr
42、oductive Maintenance(TPM)ControlControlAreas of ResponsibilityuLean Six Sigma TeamuChampion/SponsoruTPM TeamnOperatornSupervisornMaintenance40Total Productive Maintenance(TPM)ControlControl精益6Sigma团队的任务u确定一个TPM项目的需求u收集有关维护成本,延迟(时延或操作延迟,设备利用率以及质量问题的历史数据u与操作员进行深入沟通以了解他们的期望41Total Productive Maintenanc
43、e(TPM)ControlControlLean Six Sigma Team RoleuDetermine the need for a TPM ProjectuGather history of maintenance cost,delay,machine availability,and quality problemsuInterview Operators to get their prospective42Total Productive Maintenance(TPM)ControlControlu现场活动n组成TPM团队l负责设备维护的人员l操作员l一线管理人员n准备必要的装备
44、n帮助TPM团队诊断异常n协助跨功能培训n收集整理故障标牌的拷贝并生成工作明细表n提供人力资源方面的支持精益6Sigma团队的任务43Total Productive Maintenance(TPM)ControlControlLean Six Sigma Team RoleuOn floor activitiesnAssemble the TPM TeamlMaintenance personnellOperatorslFirst line supervisionnProvide necessary equipmentnHelp team diagnose abnormalitiesnAss
45、ist skilled tradesnCollect copies of defect tags and generate a work listnProvide people resources44Total Productive Maintenance(TPM)ControlControl倡导者/发起人的角色u一旦完成现场工作,接下来将:n形成工作任务并跟踪其完成情况n协助建立和引入正确的定期维护明细表n协助维持改善结果n评估设备综合利用率OEEn展示TPM的改善的成就45Total Productive Maintenance(TPM)ControlControlChampion/Spo
46、nsor RoleuUpon Completion of On Floor EventnGenerate and track completion of work ordersnAssist in creation and posting of accurate Periodic Maintenance List nAssist in sustaining the gainsnEvaluate Overall Equipment EffectivenessnDisplay TPM improvements46Total Productive Maintenance(TPM)ControlCon
47、trol现场主管的角色u指导并推广TPM概念u监控现场的设备管理,保养及机器清洁工作的进行u激发操作员的主人翁意识u对操作员授权u为TPM活动提供时间方面的准备u促进生产与维护双方的合作47Total Productive Maintenance(TPM)ControlControlSupervisors RoleuCoach and promote TPM ConceptsuMonitor ongoing housekeeping and machine cleanlinessuPromote Operator ownershipuEmpower Operators uProvide tim
48、e for TPM activitiesuPromote cooperation between Production and Maintenance48Total Productive Maintenance(TPM)ControlControl维护人员的角色“专业的管理者”u有计划的实施所有的定期保养并根据需要采取维修措施;u使用振动分析,磨损度分析,热感应等预测工具;u建立维护设备的保养记录u与操作员协同工作并提供技术支持u执行设备大修,综合调试u负责执行一些特殊技能的任务,风险安全性高的作业u促进TPM49Total Productive Maintenance(TPM)Control
49、ControlMaintenance Role“The Specialized Caretakers”uPerform all planned preventative maintenance and take corrective action as neededuUse predictive tools such as vibration analysis,wear particle analysis,and thermographyuDocument equipment maintenance historyuCooperate with Operators and provide te
50、chnical assistanceuPerform equipment overhaul,complex adjustmentsuProvide special skill tasks,high safety risk tasksuPromote TPM 50Total Productive Maintenance(TPM)ControlControl操作员角色“一线管理者”u清洁和缺陷检查u执行基本的润滑,多点检测的工作u按照核准清单的项目进行定期保养u按计划执行日常清洁和整理u识别刚刚发生的设备异常u根据需要协助维护人员进行维修u执行基本的调试工作u改善提案u促进TPM51Total P