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1、ProcessCertificationTPMQCPCRoot Cause/CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinic ActivityTotal Productive Maintenance ACE Manufacturing Qualifying Level 1程序验证程序验证全面性生产全面性生产维护维护质量诊断程序质量诊断程序图表图表根本原因根本原因修正行动修正行动减少生产减少生产准备准备标准化标准化作业作业防误措施防误措施市场反响市场反响分
2、析分析6S质量诊断质量诊断行动行动全面生产性维护 ACE 生产部门合格水平 2Total 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！TPM 全面生产性维护3TPM Key Concept TPM的重要概念Left neglected.Eq
3、uipment Breaks Down如果不重视设备很快就会坏TPMs focus is to prevent problems before equipment breaks.TPM 的焦点是要在设备出故障以前以前防止问题出现。In the past,maintenance focusedon 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。4Total Productive Maintenance Total Productive Maintenance is a New Way of Workingis a New Way
4、 of Working全面生产性维护是一种全新的工作方式全面生产性维护是一种全新的工作方式全面生产性维护是一种全新的工作方式全面生产性维护是一种全新的工作方式TPM Attitude:TPM Attitude:TPMTPM态度：态度：态度：态度：“We are all responsible for our“We are all responsible for our equipment.equipment.“我们所有人对我们的设备负责。我们所有人对我们的设备负责。我们所有人对我们的设备负责。我们所有人对我们的设备负责。Old Attitude:Old Attitude:Old Attitud
5、e:过去的态度：过去的态度：过去的态度：“I operate,you fix.“I operate,you fix.“I operate,you fix.“我操作，你修理。我操作，你修理。我操作，你修理。“I fix,you design.“I fix,you design.“I fix,you design.“我处理，你设计。我处理，你设计。我处理，你设计。“I design,you operate.“I design,you operate.“I design,you operate.“我设计，你操作。我设计，你操作。我设计，你操作。5Hidden Defects隐藏的问题隐藏的问题Fai
6、lures故障故障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、腐蚀变磨损、松驰、泄露、灰尘、污垢、腐蚀变形、原材料粘黏、外表磨损、裂缝、过热、形、原材料粘黏、外表磨损、裂缝、过热、震动、噪音及其它不正常现象。震动、噪音及其它不正常现象。Tip of the Iceberg冰山的顶端6Ty
7、pical Causes of Machine Breakdown 典型的机械故障原因Failure toadd oil.没有加油Grit and chipsin revolvingor sliding parts旋转或滑动零件中的砂砾和碎片Contaminationof sensors,contacts and Connectors传感器、触敏器、连接器污染Dirt and dust on cooling fan冷却风扇上有灰尘和污垢ComponentFailure组件失灵I wonder whatsgoing to fail next?我在想下面还会出什么我在想下面还会出什么问题呢？问题呢
8、？7TPM Techniques TPM技术Normal operating Range正常操作范围正常操作范围Danger!危险！危险！Simplify and Document TPM Activities.简化并记录TPM行动Use visual techniques to indicate whats right/whats wrong.运用直观技术来演示什么是 对的/什么是错的。PM pleted?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
9、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8TPM Benefits TPM的益处Reduced maintenance costs减少维护费用Breakdown maintenance is 10 times more costly th
10、an planned maintenance故障维修费用是有方案进行维护费用的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,pressed 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
11、time,longer life缩短停工时间，寿命更长912 TPM Qualifying ActivitiesACE Element Awareness TrainingLock Out/Tag Out awareness training available for all employees(with annual refresher)Operators of high hazard equipment informed of machine specific hazardsAssessment of machine specific safeguarding(SP-008)issues
12、Lock Out/Tag Out Equipment AvailableReview OnlyAction ItemsAssess all Equipment A,B&CImplement written Lock Out/Tag Out procedureWalk around safety check on 100%of A/B equipmentPM Schedule for 100%of A/B equipmentCleaning on 100%of A/B equipmentTrack downtime historyTop ten downtime equipment identi
13、fied1012 项TPM 合格行动ACE 内容认知培训锁定/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11PURPOSE of Lockout/Tagout锁定锁定/标识的目的标识的目的To prevent you or someone else from inadvertently turning a po
14、wer 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以防你或它人意外开动电源而造成可能的伤害甚至死亡伤害甚至死亡Lockout/Tagout Review:锁定锁定/标识检查标识检查12Lockout 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 en
15、ergizing 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局部带电。Lockout/Tagout Review:锁定锁定/标识检查标识检查13Tagout 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,
16、must notmust not be operated.是将一标签或明显的警告标志紧附于设备上 以说明不能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。Lockout/Tagout Review:锁定锁定/标识检查标识检查14WARNING 警告NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.决不要从它人处接受锁定设备的钥匙。决不要从它人处接受锁定设备的钥匙。THE ASS
17、OCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOCK OR TAG.唯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。有经授权负责运用锁或标签的人员可以拿掉该锁或标签。Lockout/Tagout Review:锁定锁定/标识检查标识检查15ACTION ITEM 1:Assess All Equipment行动内容行动内容1：评估所有设备：评估所有设备By“Equipment we mean any machine that was a capita
18、l 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
19、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设备设备16Category A:Category A:Critical equipment for which an alternate machine is not feasible,because:A A类：类：类：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 wou
20、ld be too costly/time consuming to transition to the alternate太贵/需花太多时间进行替换 Category C:Category C:Equipment for which it is relatively easy to find a replacement or alternate C C类：类：类：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$2,500Standard spare parts like
21、 drive motors are available off-the-shelf可获得的常用标准备件如驱动马达 Category B:Category B:All other equipment/machines B B类：类：类：类：所有其它设备/机器ACTION ITEM 1:Assess All Equipment cont.行动内容行动内容1：评估所有设备待续：评估所有设备待续17In addition to machine category,create a table listing all machines and additional categories,such as:除
22、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效劳卡？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 m
23、achine 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ACTION ITEM 1:Assess All Equipment cont.行动内容行动内容1：评估所有设备待续：评估所有设备待续18Possible Categories:可能的分类：GoodGood:Equipment which retains all of its original functions,accuracy a
24、nd reliability.好好好好：设备保持所有原来的功能，精确并可靠。Average:Average:Equipment which has lost some of its original functions or accuracy.Its output normally meets the required specifications.一般一般一般一般：设备丧失了一些最初的功能或精确度。其产品符合要求的标准。Poor:Poor:Equipment which is no longer accurate or reliable.In order to produce accepta
25、ble output,this equipment requires operator intervention well beyond the original level.差：差：差：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预。ACTION ITEM 1:Assess All Equipment cont.行动内容行动内容1：评估所有设备待续：评估所有设备待续19ACTION ITEM 2:Write Machine-Specific Lockout ProceduresLockout procedures must be written and
26、 implemented for each machineGeneral procedures are in effect for SullairProcedures need to be written jointly with facilities maintenance20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21Cosmetic Cleaning禁止化装品禁止化装品You get a better looking piece of equipment as a benefit but not as
27、You get a better looking piece of equipment as a benefit but not as the only objectivethe only objective你可以使机器看起来更漂亮，但这不是唯一的目的你可以使机器看起来更漂亮，但这不是唯一的目的你可以使机器看起来更漂亮，但这不是唯一的目的你可以使机器看起来更漂亮，但这不是唯一的目的You clean to improve a machines You clean to improve a machines performance-not its appearanceperformance-no
28、t its appearance清洁是为提高机器的性能清洁是为提高机器的性能清洁是为提高机器的性能清洁是为提高机器的性能-而不是外表而不是外表而不是外表而不是外表Clean to InspectClean to Inspect清洁以检查清洁以检查清洁以检查清洁以检查Inspect to DetectInspect to Detect检查以发现检查以发现检查以发现检查以发现Detect to CorrectDetect to Correct发现以改正发现以改正发现以改正发现以改正ACTION ITEM 5:Initial Inspect/Clean 100%A/B行动内容 5：初步检查/清洁所有
29、A/B类设备22Accessible ponents cleaned,inspected and repaired可用的部件已清洁、检查和修好PM documentation is reviewed/updatedPM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 didnt even know there was a grease fitting here!那个怎么样
30、。我甚至不那个怎么样。我甚至不知道这儿还有个油脂知道这儿还有个油脂装置！装置！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23ACTION ITEM 6:Track Downtime History行动内容行动内容 6：追溯停工历史记录：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 非方案的非方案的Breakd
31、owns and Repairs停工并维修Planned 方案内的方案内的Operator PM 操作员PMMaintenance PM 维护PMMaintenance Downtime Goal停工维护目标Reduce Breakdowns and Repairs减少停工和维修减少停工和维修24Use 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ACTION ITEM 7:Top Ten Downtime行动内容行动内容 7：十大停工设备：十大停工设备Pareto
32、 ChartPareto 图表25What is next?下一步是什么？plete TPM training of your work group by March 7,20012001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 groupwiseannouncement of a“Drivers Meeting to discussthe necessary resources and logistics for pletingqualifying TPM activities在2月底以前，宣布召开“领导层会议，讨论必要
33、的资源和后勤以帮助完成取得合格资格的TPM行动26We want a pany that reveres people who design,build and maintain things that never break,rather than people who fix things that break.George DavidUTC Chairman and CEO我们希望公司尊敬那些设计、建造并维持不会坏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。的东西的人们，而不是那些修理会坏的东西的人们。George DavidUTC Chairman and CEOSummary 小结27Total Productive Maintenance全面生产性维护Manufacturing生产部28演讲完毕，谢谢观看！