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1、Time Based ManagementP SKBP SKB 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.LeanSigma,The Perfect Engine,LeanStrategy,and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.全员生产保养全员生产保养全员生产保养全员生产保养Total Producti
2、ve MaintenanceTotal Productive Maintenance8 8-2 2 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB目录目录目录目录 Table of ContentsTable of ContentsTPM概略概略 TPM OverviewTPM目的目的 The Aim of TPMTPM流程流程 TPM Process自主保养自主保养 Autonomous Maintenance计划保养计
3、划保养 Planned Maintenance预防工程预防工程 Preventive Engineering教育与行动教育与行动 Education&Practice保证质量保证质量 Insured QualityTPM改善活动改善活动 TPM Kaizen ActivitiesTPM活动进阶活动进阶 Advanced TPM ActivitiesTime Based ManagementP SKBP SKB 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Re
4、served.LeanSigma,The Perfect Engine,LeanStrategy,and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.TPMTPM概略概略概略概略TPM OverviewTPM Overview8 8-4 4 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB何谓何谓何谓何
5、谓 TPM TPM What is TPM What is TPM全员生产保养全员生产保养全员生产保养全员生产保养是这样一个系统是这样一个系统T Total P Productive M Maintenance is a system that 涉及工场涉及工场/维修人员维修人员Involves both shopfloor associates and maintenance associates 支持支持精益西格玛流程精益西格玛流程Supports the LeanSigma Process 保持设备最佳状态保持设备最佳状态Keeps equipment in optimal condit
6、ion 8 8-5 5 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB为何要实施为何要实施为何要实施为何要实施 TPMTPM Why Implement TPM Why Implement TPM?忽视设备基本状况忽视设备基本状况Basic Equipment conditions neglected 操作维修技能欠佳操作维修技能欠佳Insufficient operating and maintenance skills
7、 设备设计固有不足设备设计固有不足Inherent weakness in equipment design 设备恶化无人监督设备恶化无人监督Overlooked deterioration 没有遵守使用要求没有遵守使用要求Usage conditions not observed 8 8-6 6 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB宏观愿景宏观愿景宏观愿景宏观愿景 Macro VisionMacro Visio
8、nTPM世界性的公司世界性的公司World Wide Company工人自主保养工人自主保养OperatorAutonomousMaintenance预防保养预防保养Preventive Maintenance经理支持功能经理支持功能ManagerSupportFunction工程设备工程设备设计改善设计改善Eng.Equip.DesignImprovement品质改善品质改善QualityImprovement全员生产保养全员生产保养T P M高级管理层高级管理层领导领导 S M L生产准备生产准备2P西格玛改善西格玛改善Sigma Kaizen8 8-7 7 2008 TBM Consul
9、ting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKBTPMTPM目标目标目标目标 TPM GoalsTPM Goals零故障零故障 Zero Breakdowns 零缺陷零缺陷 Zero Defects 零事故零事故 Zero Accidents 全员参与全员参与 Total employee involvement 提高机器效率提高机器效率,满足节拍满足节拍速度速度Achieve Takt Rate at the highest machine effec
10、tiveness 8 8-8 8 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKBTPMTPMTPM与精益西格玛流程与精益西格玛流程与精益西格玛流程与精益西格玛流程与精益西格玛流程与精益西格玛流程 TPM and TPM and TPM and LeanSigma ProcessLeanSigma ProcessLeanSigma Process精益西格玛精益西格玛精益西格玛精益西格玛LeanLeanSigma Proces
11、sSigma Process及时及时及时及时生产生产生产生产JustJustin inTimeTime自働化自働化自働化自働化JidokaJidoka畅顺生产畅顺生产畅顺生产畅顺生产 Production SmoothingProduction Smoothing机器可靠机器可靠Machine Reliability机器高效机器高效Machine Effectiveness联动操作联动操作Linked Operations人力利用人力利用Labor Utilization制程能力制程能力Process Capability最佳机况最佳机况Optimal machine conditions制程
12、重复制程重复Process Repeatability防错装置防错装置Mistake Proofing实现流畅生产实现流畅生产,必须实行必须实行TPMTPM is essential when flow production is achieved8 8-9 9 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKBTPMTPM与传统保养与传统保养与传统保养与传统保养 TPM vs.Traditional MaintenanceT
13、PM vs.Traditional Maintenance每班每班8小时小时 8 hr shift有效时间有效时间=7小时小时40分分 Effectiveness=7 hrs 40min工人开会工人开会:10分钟分钟Operator Meeting10 min10 min设备清洁与润滑设备清洁与润滑:10分钟分钟Equipment cleaning&Lubrication 传统传统生产生产班次班次 Traditional Operating Shift:实行实行实行实行TPMTPM的班次的班次的班次的班次 TPM ShiftTPM Shift:本班开始本班开始 Shift Start品质问题品
14、质问题 Quality暂停暂停 Minor Stoppages故障停机故障停机 Breakdown调整调整 Adjustment本班结束本班结束 Shift End每班每班8小时小时 8 hr shift有效时间有效时间=6小时小时 Effectiveness=6 hrs8 8-1010 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB量度指标量度指标量度指标量度指标 MetricsMetrics整体设备效率整体设备效率 O
15、verall Equipment Effectiveness(OEE)可用效率可用效率 Availability性能效率性能效率 Performance品质效率品质效率 Quality保养效率保养效率 Maintenance Effectiveness平均故障时间间隔平均故障时间间隔 MTTF(Mean time to failure)平均无故障时间平均无故障时间 MTBF(Mean time between failure)平均维修时间平均维修时间 MTTR(Mean time to repair)Time Based ManagementP SKBP SKB 2008 TBM Consul
16、ting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.LeanSigma,The Perfect Engine,LeanStrategy,and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.TPMTPM的目的：的目的：的目的：的目的：The Aim of TPMThe Aim of TPM:改善设备运行状况改善设备运行状况To improve the equ
17、ipment operating condition 维持设备最佳性能与可靠性维持设备最佳性能与可靠性To sustain equipment at an optimal level of performance&reliability 延长设备使用寿命延长设备使用寿命To lengthen the life expectancy of equipment Time Based ManagementP SKBP SKB 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Righ
18、ts Reserved.LeanSigma,The Perfect Engine,LeanStrategy,and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.TPMTPM流程流程流程流程TPM ProcessTPM Process8 8-1313 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKBTPM
19、TPM五大支柱五大支柱五大支柱五大支柱 The 5 Pillars of TPMThe 5 Pillars of TPM自主保养自主保养 Autonomous Maintenance计划保养计划保养PlanningMaintenance预防工程预防工程PreventiveEngineering品质品质Quality 教育与行动教育与行动Education&Practice8 8-1414 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SK
20、BP SKB实施实施实施实施TPMTPM十步骤十步骤十步骤十步骤 TPM Implementation-10 StepsTPM Implementation-10 Steps1.测量工作单元上所有自动设备之测量工作单元上所有自动设备之OEEMeasure OEE for all automatic equipment in cells.2.测量各工作单元的节拍时间测量各工作单元的节拍时间Measure Takt rate performance for each area.3.将单元节拍时间与设备将单元节拍时间与设备OEE进行比较进行比较Correlate cell takt rate per
21、formance to equipment OEE.4.选择特定机器作为改善重点选择特定机器作为改善重点Select specific machine for kaizen focus.5.根据根据OEE六大损失制定改善目标六大损失制定改善目标Establish improvement goal related to the six major losses of OEE.6.选定设备改善专职队员选定设备改善专职队员Select permanent equipment improvement team members.7.发动工人进行自主保养及计划保养活动发动工人进行自主保养及计划保养活动In
22、itiate operator autonomous maintenance and planned maintenance programs.8.继续更新检查单继续更新检查单,培训工人培训工人,保证机器最佳状况保证机器最佳状况Continue to update check lists,train operators,and pursue optimal machine conditions.9.为选定设备设立为选定设备设立TPM活动之目视表现板活动之目视表现板Establish visual performance boards for TPM activities on selected
23、 equipment.10.每月将改善目标与实际结果进行比较。评价是否需要进行更多改善活动每月将改善目标与实际结果进行比较。评价是否需要进行更多改善活动,制定更制定更高的目标高的目标,或需要更换专职队员或需要更换专职队员Check results to improvement goals monthly.Evaluate need for additional kaizen activity,setting more aggressive goals,or modifying permanent team members.Time Based ManagementP SKBP SKB 2008
24、 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.LeanSigma,The Perfect Engine,LeanStrategy,and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.自主保养自主保养自主保养自主保养Autonomous MaintenanceAutonomous Maintenance8 8-1616 2008
25、TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB自主保养自主保养自主保养自主保养 Autonomous MaintenanceAutonomous Maintenance工人要学习工人要学习 A system where equipment operators learn to:进行每日检查进行每日检查 Perform daily checks按需润滑设备按需润滑设备 Lubricate equipment as needed更换简单
26、零件更换简单零件 Replace simple components进行机器小修进行机器小修 Perform minor repairs on machines帮助解决问题帮助解决问题 Assist in problem solving工人是机器发生异常的早期预警系统工人是机器发生异常的早期预警系统Operators become the early warning systemfor machine abnormalities8 8-1717 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group
27、,Inc.All Rights Reserved.P SKBP SKB自主保养五步法自主保养五步法自主保养五步法自主保养五步法 5 Steps to Autonomous Maintenance5 Steps to Autonomous Maintenance1.进行基本清洁活动进行基本清洁活动Perform basic cleaning 2.根除肮脏污染源头根除肮脏污染源头Eliminate sources of dirt and contamination 3.建立清洁润滑标准建立清洁润滑标准Establish cleaning and lubrication standards 4.教会
28、设备基本检查教会设备基本检查,进行自主设备检查进行自主设备检查Teach general inspection of equipment and Perform autonomous equipment inspection 5.培养整齐有序习惯培养整齐有序习惯Instill orderliness and organization 8 8-1818 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB工人作用工人作用工人作用工
29、人作用 Roles of OperatorsRoles of Operators预防污染预防污染 Prevent deterioration:维持基本条件维持基本条件Maintaining basic conditions 正确操作设备正确操作设备Operating equipment correctly 判断污染判断污染Measure deterioration:进行检查进行检查Inspecting 制定标准制定标准,坚持执行坚持执行Developing and adhering to standards 纠正污染纠正污染Correct deterioration:报告问题报告问题Repor
30、ting problems 协助维修协助维修Assisting in repairs 进行微调进行微调(按本地合约按本地合约)Making minor adjustments(per local contract)加入团队加入团队Participate in teams:工作中心团队工作中心团队Work center teams 解决问题团队解决问题团队Problem-solving teams 8 8-1919 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights
31、Reserved.P SKBP SKB维修人员作用维修人员作用维修人员作用维修人员作用 Roles of Maintenance PersonnelRoles of Maintenance Personnel设备保养设备保养Maintain Equipment 检验检验(拆卸拆卸)Inspect(disassembly)计划保养计划保养Planned overhauls 预防保养预防保养Preventive maintenance 教导工人学会特定保养工作教导工人学会特定保养工作Teach selected maintenance tasks to operators 设备改善设备改善Impr
32、ove Equipment 支持可靠性及可维修性改善支持可靠性及可维修性改善Support R&M improvement 实施预测技术实施预测技术Implement predictive technologies 纠正设计不足纠正设计不足Correct design weaknesses 搞好供方合作搞好供方合作Partner with vendors 8 8-2020 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB设备
33、检查表设备检查表设备检查表设备检查表 Equipment Inspection ChecklistEquipment Inspection Checklist初步清洁初步清洁 Initial Cleaning螺母、螺栓等有无松动、摇摆、遗失螺母、螺栓等有无松动、摇摆、遗失?Any nuts,bolts,etc.loose,wobbly or missing?活动零件、夹具安装有无窜动活动零件、夹具安装有无窜动?Any play in moving parts or fixture mounting section?机器内部有无多余零件机器内部有无多余零件?Any unnecessary ite
34、ms located on the body of the machine?润滑系统润滑系统 Lubrication润滑油是否到达滑动部件润滑油是否到达滑动部件?Does oil reach sliding parts?润脂嘴、机油盖等是否损坏、遗失润脂嘴、机油盖等是否损坏、遗失?Any damaged or missing grease nipples,oil caps,etc.?供油装置、管路、接头有无漏油供油装置、管路、接头有无漏油?Any oil or grease leaks from supply devices,pipes,fittings?加油工人有无内外清洁加油工人有无内外清
35、洁?Are oilers clean inside or out?油标是否容易看见油标是否容易看见?Is the oil level easily visible?8 8-2121 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB设备检查表设备检查表设备检查表设备检查表 Equipment Inspection ChecklistEquipment Inspection Checklist液压系统液压系统 Hydraulic
36、s油箱装够油了吗油箱装够油了吗?Is the oil tank filled to the specified level?油泵发出异常噪音吗油泵发出异常噪音吗?Is the pump emitting any abnormal noises?卸荷阀、减压阀、节流阀防松螺母上紧了吗卸荷阀、减压阀、节流阀防松螺母上紧了吗?Are locknuts tight on relief,reducing and throttle valves?卸荷阀、控制装置运作正常吗卸荷阀、控制装置运作正常吗?Are relief valves and controls operating correctly?高压管
37、路连接变形或磨损了吗高压管路连接变形或磨损了吗?Any strain or wear in high pressure hose connections?电器系统电器系统 Electrical行程开关杠杆能够完全接触吗行程开关杠杆能够完全接触吗?Do limit switch bars strike fully?信号灯、指示灯遗失或烧坏了吗信号灯、指示灯遗失或烧坏了吗?Any missing or burned out pilot or indicator lights?配电盘、电器箱有无线路图配电盘、电器箱有无线路图?Are there wiring diagrams in the cont
38、rol panels or electrical boxes?有无多余的、损坏的、压坏的电线或软管有无多余的、损坏的、压坏的电线或软管?Any unnecessary,damaged or dented wires or flexible tubing?8 8-2222 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB设备检查表设备检查表设备检查表设备检查表 Equipment Inspection ChecklistEqu
39、ipment Inspection Checklist传动系统传动系统 Power Transfer DevicesV型皮带碰到带轮槽底了吗型皮带碰到带轮槽底了吗?Do V-belts hit the bottom of pulley grooves?皮带有无损坏、爆裂、破裂皮带有无损坏、爆裂、破裂?Any damage,cracking or splitting of the belts?滚柱链条的销轴与轴承之间有无足够润滑油滚柱链条的销轴与轴承之间有无足够润滑油?Is there sufficient lubrication between pins and bushings of rol
40、ler chains?转轴有无过热、振动、噪音转轴有无过热、振动、噪音?Any shaft overheating,vibration or noise?联接系统有无锁键、夹紧螺栓松动造成的窜动联接系统有无锁键、夹紧螺栓松动造成的窜动?Any play due to loose keys or clamping bolts on couplings?齿轮机构有无过量的躁音、发热、振动齿轮机构有无过量的躁音、发热、振动?Any excess noise,heat or vibration in gear mechanisms?8 8-2323 2008 TBM Consulting Group,
41、Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB设备检查表设备检查表设备检查表设备检查表 Equipment Inspection ChecklistEquipment Inspection Checklist螺母螺栓螺母螺栓 Nuts and Bolts登记记号允许松紧度检查吗登记记号允许松紧度检查吗?Do registration marks permit tightness checks?螺母螺栓型号及尺寸正确吗螺母螺栓型号及尺寸正确吗?Are nuts and bol
42、ts of the suitable types or sizes used?垫片尺寸正确垫片尺寸正确,且类型相配吗且类型相配吗?Are washers of proper size,and are they consistently used?螺栓有从螺母凸出螺栓有从螺母凸出23圈螺纹吗圈螺纹吗?Do bolts protrude 2 3 threads from the nuts?气动系统气动系统 Pneumatics截止阀及球阀漏气吗截止阀及球阀漏气吗?Any stop valve,ball valve leaks?有坏了或多余的手把吗有坏了或多余的手把吗?Any broken or u
43、nnecessary handles?已关闭的阀仍有气流吗已关闭的阀仍有气流吗?Does any air flow through closed valves?有任何不必要的装置或喉管吗有任何不必要的装置或喉管吗?Are any unnecessary devices,hoses or pipes present?所有喉管都整齐及易于识别吗所有喉管都整齐及易于识别吗?Are pipes and hoses orderly and readily identifiable?压力表指示的都是正确设定的压力吗压力表指示的都是正确设定的压力吗?Do pressure gauges clearly in
44、dicate the correct set pressure?8 8-2424 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB进行基本清洁进行基本清洁进行基本清洁进行基本清洁 Perform Basic CleaningPerform Basic Cleaning做好清洁检查做好清洁检查 Clean to inspect暴露隐藏不足暴露隐藏不足 Expose hidden defects找出脏污源头找出脏污源头 Dete
45、rmine source of contamination识别难于清洁之处识别难于清洁之处 Identify hard to reach areas准备蓝色标签工作准备蓝色标签工作 Prepare for blue tag exercise8 8-2525 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB消灭脏污源头消灭脏污源头消灭脏污源头消灭脏污源头 Eliminate Sources Of Dirt&Contaminat
46、ionEliminate Sources Of Dirt&Contamination脏污原因脏污原因 Causes of Contamination:发生液体泄漏发生液体泄漏 Fluid leaks 碎片容器很差碎片容器很差 Poor chip containment 工作不佳工作不佳 Poor 5S practices 工作区有溅洒工作区有溅洒 Work area spills 过滤性能不好过滤性能不好 Poor filtration 没有清洁标准没有清洁标准 No cleaning standards 无工作自豪感无工作自豪感 Poor work pride 环境问题恶劣环境问题恶劣 En
47、vironment 8 8-2626 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB建立清洁与润滑标准建立清洁与润滑标准建立清洁与润滑标准建立清洁与润滑标准Establish Cleaning&Lubrication StandardsEstablish Cleaning&Lubrication Standards 从工人开始进行基本的清洁、检查及润滑活动从工人开始进行基本的清洁、检查及润滑活动Begin basic op
48、erator cleaning,inspecting and lubricating activities 制定临时标准制定临时标准 Establish provisional standards 进行重点训示进行重点训示 Create one point lesson 确定活动频次确定活动频次 Establish frequency of activities 月检、周检、日检清单月检、周检、日检清单Monthly,weekly and daily check list 制做检查表制做检查表 Develop check list 8 8-2727 2008 TBM Consulting Gr
49、oup,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB重点训示重点训示重点训示重点训示 One-Point LessonOne-Point Lesson1.0 目的目的/范围范围:根据根据3600路线检查单脂具体检查步骤制定详细的工作指示路线检查单脂具体检查步骤制定详细的工作指示2.0 责任责任:工人工人3.0 安全安全:标准的工人保护设备标准的工人保护设备:防护眼镜防护眼镜,听觉保护用具听觉保护用具,手套手套,钢头鞋钢头鞋4.0 工作指示工作指示第第1步步:本工作指示用于
50、与本工作指示用于与3600路线检路线检查单有关的工作查单有关的工作第第2步步:本工作指示用于本工作指示用于3600吨冲压机吨冲压机周围的检查工作周围的检查工作35第第3步步:检查模具加热炉温度及设定值。检查模具加热炉温度及设定值。绝对最低设定值应为绝对最低设定值应为800度度8 8-2828 2008 TBM Consulting Group,Inc.All Rights Reserved.2008 TBM Consulting Group,Inc.All Rights Reserved.P SKBP SKB进行自主保养检查进行自主保养检查进行自主保养检查进行自主保养检查Perform Aut