TPM全面生产性维护概述.pptx

*,*,Total Productive Maintenance,OFFICE,办公室,1,Process,Certification,QCPC,Root Cause/,Corrective,Action,Set-Up,Reduction,Standard,Work,Mistake,Proofing,Market,Feedback,Analysis,6S,Quality,Clinic Activity,Total Productive Maintenance,ACE Office Qualifying Level,TPM,2,程序验证,全面性生产,维护,质量诊断程序,图表,根本原因,修正行动,减少生产,准备,标准化,作业,防误措施,市场反馈,分析,6,S,质量诊断,活动,全面生产性维护,ACE,办公室合格水平,3,No alternate exists,or,15、最具挑战性的挑战莫过于提升自我。,like it is your own!,Typical Causes of Equipment Breakdown典型的设备故障原因,Out of paper,决不要从它人处接受锁定设备的钥匙。,Revision Date:3/,Total Productive Maintenance is a New Way of Working全面生产性维护是一种全新的工作方式,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。,Note:Evaluation for machine only.,只影响到这台机器1,Lorem ipsum dolor sit amet,consectetur adipiscing elit.,Root Cause/,13、不知香积寺，数里入云峰。,We want a company that reveres people who design,build and maintain things that never break,rather than people who fix things that break.,Total 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,4,TPM Key Concept TPM,的重要概念,Left neglected.Equipment 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,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。,5,Total Productive Maintenance is a New Way of Working,全面生产性维护是一种全新的工作方式,TPM Attitude:,TPM,态度：,“We are all responsible for our equipment.”,“,我们所有人对我们的设备负责。”,Old Attitude:,过去的态度：,“I operate,you fix.”,“,我操作，你修理。”,“I fix,you design.”,“,我处理，你设计。”,“I design,you operate.”,“,我设计，你操作。”,6,A failure is just thetip of the iceberg!,Hidden,Defects,隐藏的问题,Failures,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、腐蚀变形、原材料粘黏、表面磨损、裂缝、过热、震动、噪音及其它不正常现象。,Tip of the Iceberg,冰山的顶端,7,Component,Failure,部件,失灵,Typical Causes of Equipment Breakdown,典型的设备故障原因,Failure to replace toner,更换,墨盒失败,Paper jam,卡,纸,I wonder whats,going to fail next?,我想下面还会出什么,问题呢？,Dirt and contamination,灰,尘和污染,Out of paper,缺,纸,8,TPM Benefits TPM,的益处,Reduced maintenance costs,减少维护费用,Breakdown maintenance is 10 times more costly than planned maintenance,故障维修费用是有计划进行维护费用的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,compressed 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 time,longer life,缩短停工时间，寿命更长,9,qualifying TPM activities,对瓶颈设备给予特殊的关注。,C类：相对容易用其它设备替代的设备,We want a company that reveres people who design,build and maintain things that never break,rather than people who fix things that break.,Responsible Individual,Daily PM Tasks,the following:,18:35:3718:35:3718:35Tuesday,October 25,2022,有些2,13、不知香积寺，数里入云峰。,14、意志坚强的人能把世界放在手中像泥块一样任意揉捏。,强烈推荐跟进以确保操作员PM的实施：,TPM Qualifying Criteria,(Business Process/Office),ACE Element Awareness Training for all employees,Equipment assessment A,B&C,PM,plan,for 100%of category“A”equipment,Whats Ahead,BRONZE TPM CRITERIA,Implement PM Plan,Track downtime history for vital machines,Process Management,Identify Key Processes,Identify Waste Elimination Opportunities,Qualifying,Awareness&,Baseline,10,TPM,合格,标准,(,商业,程序,/,办公,室,),ACE,内容,认知培训，针对所有员工,A,B&C,类,设备评估,所,有“,A”,类设备的,PM,计划,前面,是什么？,铜,牌,TPM,标准,执,行,PM,计划,追,溯重要机器的停工历史记录,程序,管理,确定,关键程序,确定,浪费消减方法,合格,认,知,&,基,线,11,Sullair Safety Lockout Program Procedure,寿力安全设备锁定计划程序,Lockout Procedures:,锁定程序：,Actions necessary to lockout a power source of any machine to be repaired,serviced or set-up,where unexpected motion,or an electrical or other energy source,would cause personal injury or equipment damage.,在任何机器的电源需要修理、维护或准备的地方都必须进行锁定，否则意外的动作或其它电源将会引起人身的伤害或设备的损坏。,Lockout Tag:,锁,定标签,12,WARNING,警告,NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.,决不要从它人处接受锁定设备的钥匙。,THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE,ONLY,PERSON AUTHORIZED TO REMOVE THE LOCK OR TAG.,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。,Lockout/Tagout Review:,锁定/标识检查,13,ACTION ITEM 1:,Assess All Equipment,活动,内容1：评估所有设备,By“Equipment”we mean any machine that was a capital 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.,我们根据设备的独特性和重要性对所有设备进行分类，以确保我们的注意力首先放在正确的设备上。对瓶颈设备给予特殊的关注。,14,?,ACTION ITEM 1:,Assess All Equipment,(cont.),活动,内容1：评估所有设备,（待续）,Category A:,Critical equipment for which an alternate machine is not feasible,because:,A,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 would be too costly/time consuming to transition to the alternate,太贵/需花太多时间进行替换,Category C:,Equipment for which it is relatively easy to find a replacement or alternate,C,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$2,500,费用低于$,2,500,Standard spare parts(like drive motors)are available off-the-shelf,可获得的常用标准备件（如驱动马达）,Category B:,All other equipment/machines,B,类：,所有其它设备/机器,15,In addition to machine category,create a table listing all machines and additional categories,such as:,除了机器分类，还应作一表格列出所有机器和附加类别，如：,Item description/ID number,物品,描述/,ID,号,Category,种类,Item Owner,物品,主人,Identify equipments title holder and a“local”owner if appropriate,确定,设备名义上的拥有者及一“本地”主人，如有必要的话,Department managers signature,部门,经理的签名,ACTION ITEM 1:,Assess All Equipment,(cont.),活动,内容1：评估所有设备,（待续）,Department Manager,Category A/B/C List A/B/C,类,清单,Copier,Epson Printer,Air conditioner,Personal Comp.,Personal Comp.,Personal Comp.,Personal Comp.,B,C,A,C,C,C,C,User Name,User Name,User Name,User Name,User Name,User Name,User Name,Co.Name,Co.Name,Co.Name,Co.Name,Co.Name,Co.Name,Co.Name,43565,3217,e7654,4082,3189,2180,2345,Item,物品,ID#Category,类型,Title Holder,名义,主人,Local Owner,本,地主人,16,Example:,Office Equipment Assessment Worksheet,Total Productive Maintenance,Office Equipment Assessment Worksheet,Note:Evaluation for machine only.Not for networks,Equipment name,Dept.,Equipment ID#,Responsible Individual,Productivity,1.How often is the equipment used each day?80%or above5,50-80%3,50%or below2,2.Is there backup/alternate equipment available?No(one of a kind)5,Yes(another dept.)3,Yes(in dept)1,3.To what extent will a failure of this equipment affect other office processes?Stops entire dept.process5,.Do other processes run through this equipment?Slows other dept.processes4,Only affects this machine1,4.To what extent will a failure of this equipment affect on-time delivery?Decisively5,Somewhat2,Not Significantly1,Quality,5.How will the processes run on this equipment affect final quality of theDecisively5,finished product/service?Somewhat2,Not significantly1,Maintenance,6.What is the average monthly cost of repairs to this equipment?$1000 or more5,$0-$10004,Service Contract2,7.What is the average time it takes to repair this equipment?Over 3 hours5,(Help desk response,if applicable)1-3 hours4,0-1 hour2,Safety,Environment,Housekeeping,8.Do safety enhancements need to be applied?Does the equipment need a housekeeping schedule?Both answers are“yes”5,One answer is“yes”3,“,A”Machine:32-,40none are yes0,“B”Machine:22-31,Machine Category:Total Score:,“C”Machine:21 or less,17,范例,:,办公,室设备评估,工作,表,全面,生产性维护,办公,室设备评估工作表,注意,:,仅,用于机器评估。,不,用于网络系统。,设备,名称,部门,设备,ID#,负责,人员,生,产力,1.,该,设备第日使用有多频繁,?80%,或,以上,5,50-80%3,50%,或,以下,2,2.,有,可用的后备/替代设备吗,?,没,有,(,其中,一种,)5,是,的,(,另,一部门,)3,是,的,(,部门,内,)1,3.,该,设备失灵会在多大范围内影响其它设备,?,阻,滞了整个部门的运行,5,.,其它,设备的运行经过该设备吗,?,减,慢了其它部门的运行,4,只,影响到这台机器,1,4.,该,设备的失灵会在多大范围内影响正在进行的发送,?,很,明显地,5,有,些,2,不,明显,1,品质,5.,该,设备的运行将怎样影响产品/服务的最终品质,?,很,明显,5,有,些,2,不,明显,1,维护,6.,每,月花在修理该设备上的平均费用有多少,?$1000,或,以上,5,$0-$10004,售,后服务,2,7.,平均,花多少时间修理该设备,?3,小时,以上,5,(Help desk response,if applicable)1-3,小时,4,0-1,小时,2,安全、,环境和内务管理,8.,需要,增加安全性吗,?,该,设备需要内务管理进度表吗,?,答案,都是“是”,5,一,个答案是“是”,3,“,A”,类,机器,:32-,40,没,有答案是“是”,0,“B”,类,机器,:22-31,机器,类型,:,总,分,:,“C”,类,机器,:21,或,更少,18,ACTION ITEM 2:,PM Plan on 100,%,“A”,活动,内容2：针对所有,A,类机器的,PM,计划,Operator PM defined for 100%of Category A machines.,为,所有,A,类机器制定操作员,PM,Determine if there are any“A”machines in your area,确定,你的工作区域是否有,A,类机器,If there are,there must be a PM plan:,如果,有，应有一个,PM,计划：,In-house,内部,Outside Contractor,外部,合约人,Rev:B,Revision Date:3/,25/98,Operator Preventive Maintenance Service Card,Machine:,Okuma LC-30,4 Axis,BT#3054,Daily PM Tasks,1.,Check running sight.,2.,Check and fill Waylube:Vactra 2.,3.,Check tramp oil and scrounger.Empty tramp oil if required.,4.,Check and fill coolant:PML 9333.,Weekly PM Tasks:,Do,Daily,tasks,and,the following:,1.,Check and fill spindle lube:DTE 24.,2.,Check and fill air lubricator:DTE 24.(Shut off and drain air to fill),3.,Check motor fan filter(Change if necessary):Cat.#030058.,4.,Check and fill hydraulic tank:DTE 24.,5.,Check roll filter(Change if needed):Cat.#027793.,Monthly PM Tasks:,Do,all,tasks on this sheet.,1.,Grease chuck fittings,1 shot.,2.,Grease 1 fitting,2 shots,both turrets.,3.,Clean air filter.,4.,Change air filter:Cat.#021183.,19,ACTION ITEM 2:,PM Schedule on 50%A&B,(contd),活动,内容2：针对50%,A,和,B,类机器的,PM,进度表,（待续）,Following is,highly recommended,to make Operator PM effective:,强烈,推荐,跟进以确保操作员,PM,的实施：,Use a “Visible at-a-glance”system(Such as a color-coded PM Status board)within the work area to indicate the actual status of“Operator PM”tasks.,使用一眼就能看见的系统(如使用颜色代码,PM,状态板)在单元中表明“操作员,PM”,任务的实际状态,Must be easy to understand,No book or folder to read,必须容易理解,无需翻书或文件夹,20,What is next?,下一步是什么？,Complete TPM training of your work group,by March 7,2001,2001,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 groupwise,announcement of a“Drivers”Meeting to discuss,the necessary resources and logistics for completing,qualifying TPM activities,在2月底以前，宣布召开“领导层”会议，,讨论必要的资源和后勤以帮助完成,取得合格资格的,TPM,活动,21,We want a company that reveres people who design,build and maintain things that never break,rather than people who fix things that break.,George David,UTC Chairman and CEO,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。,George David,UTC Chairman and CEO,Summary,小结,22,Total Productive Maintenance,OFFICE,办公,室,23,9,、静夜四无邻，荒居旧业贫。,10月-26,10月-26,Sunday,October 4,2026,10,、雨中黄叶树，灯下白头人。,02:40:58,02:40:58,02:40,10/4/2026 2:40:58 AM,11,、以我独沈久，愧君相见频。,10月-26,02:40:58,02:40,Oct-26,04-Oct-26,12,、故人江海别，几度隔山川。,02:40:58,02:40:58,02:40,Sunday,October 4,2026,13,、乍见翻疑梦，相悲各问年。,10月-26,10月-26,02:40:58,02:40:58,October 4,2026,14,、他乡生白发，旧国见青山。,04 十月 2026,2:40:58 上午,02:40:58,10月-26,15,、比不了得就不比，得不到的就不要。,。,十月 26,2:40 上午,10月-26,02:40,October 4,2026,16,、行动出成果，工作出财富。,2026/10/4 2:40:58,02:40:58,04 October 2026,17,、做前，能够环视四周；做时，你只能或者最好沿着以脚为起点的射线向前。,2:40:58 上午,2:40 上午,02:40:58,10月-26,9,、没有失败，只有暂时停止成功！。,10月-26,10月-26,Sunday,October 4,2026,10,、很多事情努力了未必有结果，但是不努力却什么改变也没有。,02:40:58,02:40:58,02:40,10/4/2026 2:40:58 AM,11,、成功就是日复一日那一点点小小努力的积累。,10月-26,02:40:58,02:40,Oct-26,04-Oct-26,12,、世间成事，不求其绝对圆满，留一份不足，可得无限完美。,02:40:58,02:40:58,02:40,Sunday,October 4,2026,13,、不知香积寺，数里入云峰。,10月-26,10月-26,02:40:58,02:40:58,October 4,2026,14,、意志坚强的人能把世界放在手中像泥块一样任意揉捏。,04 十月 2026,2:40:58 上午,02:40:58,10月-26,15,、楚塞三湘接，荆门九派通。,。,十月 26,2:40 上午,10月-26,02:40,October 4,2026,16,、少年十五二十时，步行夺得胡马骑。,2026/10/4 2:40:58,02:40:58,04 October 2026,17,、空山新雨后，天气晚来秋。,2:40:58 上午,2:40 上午,02:40:58,10月-26,9,、杨柳散和风，青山澹吾虑。,10月-26,10月-26,Sunday,October 4,2026,10,、阅读一切好书如同和过去最杰出的人谈话。,02:40:58,02:40:58,02:40,10/4/2026 2:40:58 AM,11,、越是没有本领的就越加自命不凡。,10月-26,02:40:58,02:40,Oct-26,04-Oct-26,12,、越是无能的人，越喜欢挑剔别人的错儿。,02:40:58,02:40:58,02:40,Sunday,October 4,2026,13,、知人者智，自知者明。胜人者有力，自胜者强。,10月-26,10月-26,02:40:58,02:40:58,October 4,2026,14,、意志坚强的人能把世界放在手中像泥块一样任意揉捏。,04 十月 2026,2:40:58 上午,02:40:58,10月-26,15,、最具挑战性的挑战莫过于提升自我。,十月 26,2:40 上午,10月-26,02:40,October 4,2026,16,、业余生活要有意义，不要越轨。,2026/10/4 2:40:58,02:40:58,04 October 2026,17,、一个人即使已登上顶峰，也仍要自强不息。,2:40:58 上午,2:40 上午,02:40:58,10月-26,MOMODA POWERPOINT,Lorem ipsum dolor sit amet,consectetur adipiscing elit.Fusce id urna blandit,eleifend nulla ac,fringilla purus.Nulla iaculis tempor felis ut cursus.,感谢您的下载观看,专家告诉,