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1、Measure MeasureAnalyze AnalyzeControl ControlImprove ImproveLean Six Sigma Lean Six Sigma全面生产维护(TPM)TPM TPM 团队组织 设备综合利用率OEE TPM 活动步骤RD011202Measure MeasureAnalyze AnalyzeControl ControlImprove ImproveLean Six Sigma Lean Six SigmaTotal Productive Maintenance(TPM)TPM TPM Team Organization Overall Equi
2、pment Effectiveness TPM PhasesRD011202Control ControlTotal Productive Maintenance(TPM)3精益6 过程改善流程分析 分析 控制 控制 改进 改进定义 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 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 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 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
3、案控制 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 测量定义 定义 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 RACI Quad 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&R Cp&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 ANOVA C&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
4、图 控制图 柏拉图 互动回顾 愚巧法Revised 1-12-02Control ControlTotal Productive Maintenance(TPM)4Lean Six Sigma Improvement Process Road MapAnalyze Analyze Control Control Improve ImproveDefine Identify Problem Develop List of Customers Develop List of CTQs from Voice of the Customer Finalize Project Focus and Key
5、 Metrics Complete PDFMeasure Map Business Process Map Value Stream Develop DataCollection Plan Conduct MeasurementSystem Analysis Collect Data Conduct Process Capability AnalysisAnalyze Propose Critical Xs Prioritize Critical Xs Verify Critical Xs Estimate the Impact of Each X on Y Quantify the Oppo
6、rtunity Prioritize Root Causes Conduct Root Cause Analysis on Critical XsImprove Critical Xs Confirmed Develop Potential Solutions Select Solution Optimize Solution Pilot SolutionControl Implement Process Changes and Controls Write Control Plan Calculate Final Financial/Process Metrics Transition Pr
7、oject to Future Owners Identify Project Translation OpportunitiesMeasure Measure Define Define Project ID Tools Project Definition Form Net Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management Process RACI Quad Charts Process Mapping Value Analysis Bra
8、instorming Multi-Voting Techniques Pareto Charts C&E/Fishbone Diagrams FMEA Check Sheets Run Charts Control Charts Gage R&R Cp&Cpk SupplyChainAccelerator Analysis Multi-Vari Box Plots Interaction Plots Regression ANOVA C&E Matrices FMEA Brainstorming Pull Systems Setup Reduction TPM Process Flow Ben
9、chmarking Affinity DOE Hypothesis Testing Force Field Tree Diagrams Gantt Charts Check Sheets Run Charts Histograms Scatter Diagrams Control Charts Pareto Charts Interactive Reviews Poka-YokeRevised 1-12-02Control ControlTotal Productive Maintenance(TPM)5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
10、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Control ControlTotal Productive Maintenance(TPM)6Learning Objectivesu Learn a method to:n Integrate operational productivity factors applicable in process industries in a single comprehensive measurementn Eliminate factors contributing to
11、 equipment failuren Improve accessibility for cleaning and maintaining equipmentn Use predictive maintenance as a diagnostic tooln Implement maintenance auditsControl ControlTotal Productive Maintenance(TPM)7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;Co
12、ntrol ControlTotal Productive Maintenance(TPM)8Whats in It for Me?u Optimized process operations and maintenanceu A method to replace the traditional approach of detecting and correcting faulty conditions as they occuru A proactive system which monitors and corrects causesu An operations strategy ba
13、sed on understanding the cause and effect system affecting the major contributors to process performanceControl ControlTotal Productive Maintenance(TPM)9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。Control ControlTotal Productive Maintenance(TPM)10Total Productive Maintenance(TPM)TPM Def
14、initionu A common sense approach to monitor operations,maintain equipment,eliminate unscheduled downtime,and improve the level of cooperation between Operations and Maintenance.Control ControlTotal Productive Maintenance(TPM)11TPMu 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Control Co
15、ntrolTotal Productive Maintenance(TPM)12TPMu Achieve zero equipment breakdowns and zero defects through preventionu Establish prevention byn Maintaining normal conditionsn Early detection of abnormalitiesn Quick responseControl ControlTotal Productive Maintenance(TPM)13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
16、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Control ControlTotal Productive Maintenance(TPM)14Traditional Approach“Re-Active Maintenance”Maintenance“WE FIX”n Perform all maintenance activitiesn Perform“Fire Fighting”maintenanc
17、e when a machine breakdown occursn Order and administer all tooling,supplies,etc.n Perform Preventive MaintenanceManufacturing“WE OPERATE”n Generally does not perform any maintenance activitiesn Contacts maintenance when a machine breakdown occursn Inactive during maintenance activitiesn“Run it till
18、 it breaks”Control ControlTotal Productive Maintenance(TPM)15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 定期保养 定期保养Control ControlTotal Productive Maintenance(TPM)16Key Defini
19、tionsPreventive 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.n PM SchedulesPredictive Maintenance is a situation based method of maint
20、aining equipment.Maintenance activities are performed on equipment based on visible signals or diagnostic techniques to prevent equipment breakdowns from occurring.n Vibration Analysisn Laser Measuringn Ultrasoundn Generator Testingn Thermographyn Oil AnalysisPredictive Maintenance Predictive Mainte
21、nance Preventive Maintenance Preventive MaintenanceControl ControlTotal Productive Maintenance(TPM)17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Control ControlTotal Productive Maintenance(TPM)18Present State Analysisan
22、d Team Organizationu Assess Current Operating Conditionsn Machine utilization,productivity,etc.n Maintenance repair costs(parts and labor)n Prioritize order of TPM effortsu Assess capabilities of potential TPM Champions and Team Membersu Select TPM Champion and Team Membersn Establish initial kick-o
23、ff workshopn Establish team goalControl ControlTotal Productive Maintenance(TPM)19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Control ControlTotal Productive Maintenance(TPM)20Typical Operational Process Measurementsu Utilizati
24、on:The ratio of equipment actual operating time to the total available operating timen=Actual Operating Time/Available Timeu Efficiency:The ratio of actual product produced to a standardn=(Actual Parts/Hour)/(Standard Part/Hour)u Output:Measure of output over a specified time periodn=lbs/hr,pieces/h
25、rControl ControlTotal Productive Maintenance(TPM)21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.Control ControlTotal Productive Maintenance(TPM)22Overall Equipment Effectivenessu Overall Equipment Effectiveness(OEE)is the measure of the percent of time a piece of equipment is producing qu
26、ality product at the designed rate.Control ControlTotal Productive Maintenance(TPM)23OEE 分解:六大浪费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.设置时间浪费任何与设备调整,装配,清洁相关的作业.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.品质原因浪费为确保设备产出品的品质而采取相关的作业(过程中检查).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(AL)
27、AL)运行水平 运行水平(OL)OL)质量水平 质量水平(QL)QL)Control ControlTotal Productive Maintenance(TPM)24OEE Breakdown:The Six Big LossesBreakdowns and Minor StoppagesMalfunctions causing equipment to stop processing greater than 10 minutes(breakdowns)or less than 10 minutes(minor stoppages)SetupAny activity related to
28、 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 related to ensuring the quality of the product produced on the equipme
29、nt(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)Control ControlTotal Productive Maintenance(TPM)25六大浪费的识别练习Control Con
30、trolTotal Productive Maintenance(TPM)26Six Big Losses Identification ExerciseControl ControlTotal Productive Maintenance(TPM)27OEE 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)OEE 73%x 91%x 80%26.3-3.1-2.1=80%26.3 28.9-1.5-1.1=91%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-
31、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 hrsControl ControlTotal Productive Maintenance(TPM)28Calculating OEE ElementsLoading Time(LT)Total Hours Available for Equipment Operation=40 hrsAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)O
32、EE 73%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=26.3-3.1-2.1=21.1 hrsControl ControlTotal Productive Maintenance(T
33、PM)29世界级的OEE 性能水平承载时间(LT)同步计划运转时间及生产性防护时间可用水平(AL)运行水平(OL)质量水平(QL)OEE 90%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 90%以上OL 维持在 95%以上QL 不低于 99%Control ControlTotal Productive Maintenance(TPM)30World Class OEE PerformanceLoading Time(LT)Operation Time and PM Time is
34、 scheduled synchronizing the twoAvailabilityLevel(AL)OperatingLevel(OL)QualityLevel(QL)OEE 90%x 95%x 99%QualityFactorsBreakdownsMinor Stops,and Admin.SetupSpeed LossesIdlingReworkand ScrapOEE=85%is World Class PerformanceThe AL is consistently kept at or above 90%The OL is maintained at or above 95%
35、The QL is at or above 99%Control ControlTotal Productive Maintenance(TPM)31使设备恢复到可靠状态 使设备恢复到可靠状态消除故障 消除故障开发 开发PM PM 维护保养资料库 维护保养资料库消除缺陷 消除缺陷阶段 I阶段 II阶段 III阶段 IVTPM 阶段Control ControlTotal Productive Maintenance(TPM)32Return Equipment Return Equipmentto Reliable Condition to Reliable ConditionEliminate EliminateBreakdowns BreakdownsDevelop PM Develop PMInformation Database Information DatabaseEliminate EliminateDefects DefectsPHASE IPHASE IIPHASE IIIPHASE IVTPM Phases