TNPM-全员规范化生产维修(1)

IWPE’99JinanTotalNormalizedProductiveMaintenance---TNPM全员规范化生产维修李葆文LiBaowen广州大学GuangzhouUniversity广州，小北登峰麓景路，510091IWPE’99Jinan什么是TPM？WhatisTPM?全效率OEE全系统WholeSystem全员AllMembersParticipatingTPM大行动TPMACTION空间、时间全系统SPACE，TIME，THEWHOLESYSTEM设备管理靠全员ALLMEMBERSPARTICIPATING提高效率才成功SUCCESSRELIESONOEEINCLRESINGWhatisTheMostDifficultPointtoImplementTPMinChina?什么是在中国推行TPM的最难点？全员参加AllMembersParticipating“全员”这一理念对不对？“Allmembersparticipating”,rightorwrong?有人说：“设备维修是维修工人的事，这么先进的设备让只会操作的操作工人去维修，简直是胡闹！”Somebodysaid:”Itisanonsensethattheadvancedequipmentisrepairedbytheoperatorwhoknowsonlyoperating”Weneedtochangeourtraditionalthinkingpattern!我们应该改变传统的心智模式！Whateffectsourthinkingpattern?什么影响着我们的心智模式？经验,教训,历史,习惯,理论……experience,teaching,history,habit,theory,……“Cleartozero.”Let’schangeourthinkingpattern.让我们改变自己的心智模式。不断的使自己思想进入“归零”状态。EVENANIMALHASHISTHINKINGPATERN.即使动物都有自己的心智模式什么拴住了大象？WHATFASTENSTHEPITYELEPHANT？是细细的绳子和棍子？ISTHETHINROPEORBAR？NO！不是！THETHINKINGPATERNOFTHEELEPHANT！是大象的心智模式！Whatisthefailure?什么是故障？故障的语源：故障是人故意使设备产生障碍的。Accordingtothelinguisticsourceof“failure”inChinese,itisthepeoplewhobreakdownthemachineonpurpose.Workeristhemotherofthemachine,machineisababywhocannotsay.工人是设备的母亲，设备是不会说话的婴儿。如果每个员工象母亲对待自己不会说话的婴儿那样对待和关心设备，设备就是健康宝宝。Iftheoperatorisconcernedwithandpaycloseattentiontohisequipmentlikethemothertowardherson,thentheequipmentwillcertainlybeahealthybaby.故障是冰山的顶峰。Thefailureisthepeakofaniceberg.failure故障dirt脏污heating发热vibrating振动leaking滴漏loosening松动short-circuit短路aging老化softening软化deforming变形冰山下面这么多潜在问题，不靠“全员”关注行不行？Whyshouldwerepairacontrolboxofanoverheadtravellingcraneformorethan40timesamonth?为什么天车的控制盒一个月要修理40多次？因为：操作工人把控制盒内的导线拉断，或把控制盒沾上水而短路。Since,thewireinsidethecontrolboxisdrawnoutormadeshort-circuitbyputtingintothewatercarelesslybyoperators.+,-Faultalwaysbeginsfromminorproblems.故障总是从小处开始的。飞机失事很少会是飞机头或机翼掉下来，往往是油管堵塞或是某一个小螺丝松落。Theairplaneaccidentisseldomcausedbythecrackingdownoftheheadorthewing,butalwaysbythelostofasmallnutortheblockofanoilpipe.为什么在中国企业安装TPM会更困难？WHYISITMOREDIFFICULTTOINSTALLTPMINCHINESECOMPANIES？历史文化不同；DIFFERENTHISTORYANDCULTURE；企业员工平均素质不同；DIFFERENTAVERAGEPERSONNELQUALIFICATION；管理模式不同；DIFFERENTPATERNOFMANAGEMENT。仕TPM在中国企业安装应适应中国企业文化TPMshouldbere-tailoredtosuitthebodyofChinesecompanies.Thecomparisonofenterprisecultureindifferentcountries.中外企业文化比较项目日本企业美国企业中国企业itemJapanesecompanyAmericancompanyChinesecompany员工素质高，平均高，参差不齐低，参差不齐qualificationhigh,samehigh,differentlow,different团队合作好，同舟共济一般，有独立性差，无形组织cooperationgoodsoso,independentbad,invisiblegroup职业道德优秀良好一般responsibilityexcellentgoodgeneral流动性低高较低mobilitylowerhighlowAsuccessfulTPMinstalledinChinesecompany,threeproblemsshouldbesolved.中国企业成功的TPM，应解决好三个问题：1工人素质行不行？IsthecapabilityofoperatorssuitabletoTPM?2工人愿意不愿意？WilltheoperatorswantjoinTPMactivities?3制度允许不允许？DotherulesandregulationspermitoperatorstoparticipateTPMactivities?如何解决？--------规范HOWTOSOLVETHEPROBLEM---NORMALIZATION规范：根据企业设备实际，员工素质而制订的工作规程和行为准则。THEWORKINGPROGRAMANDTHEBEHAVIORREGULATIONACCORDINGTOTHEREALITYOFEQUIPMENTANDOPERATOR‘SQUALITY解决方案－－规范SOLUTION------NORMALIZATION1Capability:Training,education,butcannotmeettherequirementimmediatelybuildappropriatebehaviornormalizationonmaintenance，training.1员工素质：靠培训，教育，但不可能很快达到要求制订适应员工水平的维修行为规范，培训上岗。解决方案－－规范SOLUTION------NORMALIZATION2Willingness:companyculture,educationandpromoting,butsometime,distantwatercannotquenchpresentthirst.Normalizationistheinnerlawofcompany,thateverybodyshouldobey.2愿意：靠企业文化，教育，宣传，但有时远水解不了近渴。规范就是企业内部的家法，每个人都要遵守。解决方案－－规范SOLUTION------NORMALIZATION3Regulation:canbechangedtomeettherequirementofTPM.Inotherwords,iftheoperatormaintaintheequipmentaccordingtothenormalization,thentheregulationpermits.3制度：制度当然可以改变以适应TPM的需要。也就是说，只要按照规范执行，制度就是支持（允许）的。Thedifferencebetweennormalizationandstandard规范与标准有什么不同？1规范是企业内部规定，不同企业可以有所不同。而标准则是跨行业、跨企业的。2规范是动态可调的，应随设备进步，人员素质进步及时加以调整。标准则有相对较长时间的稳定性。1Normalizationistheinnerregulation,differentcompaniesmayhavedifferentnormalization.However,standardistrans-companyortrans-trade,standardistruetoeverycompany.2Normalizationisdynamicandchangeable,thenormalizationcanbealternatedalongwiththeprogressofpersonnelandequipment.However,thestandardisstableinalongerperiod.规范与ISO贯标THERELATIONSHIPBETWEENNORMALIZATIONANDISOSTANDARDIZATION规范与ISO贯标目标一致Havingthesamedestination规范是ISO标准的深入和细化NormalizationisthedetailofISOstandardizationTPM的规范化文件相当于ISO贯标的C级，D级文件ThedocumentofTPMnormalizationbelongstoclassCorDdocumententofISOstandardization规范化的内容THECONTENTENTOFNORMALIZATION现场管理规范化On-sitemaintenance备件管理规范化Sparepartsmanagement前期管理规范化Earlierstagemanagement维修管理规范化Maintenancemanagement润滑管理规范化Lubricationmanagement台帐管理规范化Filesmanagement什么是TNPM？WHATISTNPM？是循序渐进构造文明企业的修炼THESELF-CULTIVATIONTOBUILDACIVILIZEDENTERPRISE是科学的营建“绿色”企业的修炼THESELF-CULTIVATIONTOSTRUCTUREAGREENENTERPRISE是精密铸造企业灵魂的修炼THESELF-CULTIVATIONTOESTABLISHTHEENTERPRISESOULCONCLUSION:TNPM--TheChineseWayofTPM结论：TNPM－中国的TPM之路。