一份老外的TPM讲义

1ASTRATEGYFORPERFORMANCEEXCELLENCE2PerformanceExcellenceSeriesTrainingModuleElementsExecutiveOverviewParticipantmanualToolsWorkbookKnowledgeBreakthroughLecturenotesLecturenotes3TableofContentsExecutiveOverviewSession1.0Introduction……………………………………...3Session2.0RoleinLeanManufacturing…………………….8Session3.0RoleoftheOperatorinTPM…………………..18Session4.0AutonomousMaintenanceImplementation……22Session5.0EquipmentPerformance:Measurement&Management………………….564TotalProductiveMaintenanceDotheseproblemssoundfamiliar?EquipmentisalwaysbreakingdownOperatingmachinesatratedspeedscreatesdefectsSetupsandadjustmentstaketoolongMinormachinestoppagesareerodingproductivity5TotalProductiveMaintenanceAseriesofmethodstoensurethatprocessmachinesarealwaysabletoperformtheirfunctionssothatproductionisneverinterrupted.6TotalProductiveMaintenanceWhatitis:1.Optimizesequipmentefficiency2.ImplementsacompanywidePreventiveMaintenancesystem3.Involvesproductionequipmentdesigners,operators,andmaintenancedepartmentpersonnel4.InvolvementfromManagementdowntofloorworkers5.Implementedthroughsmall,selfdirectedteamactivities7TotalProductiveMaintenanceTypicalsuccessresultsafterimplementationofTPM:Breakdowns:1/30to1/100ofpriorlevelMachinedefects:1/30to1/40ofpriorlevelProductivity:30-100percentincreasesource:K.Shirose,TPMForWorkshopLeaders,p.108PerformanceExcellence:ExpandingtheStrategythroughTPMIntroductionRoleinLeanManufacturingRoleoftheOperatorinTPMAutonomousMaintenanceImplementationEquipmentPerformance:MeasurementandManagement9TheNinetypesofwaste•Overproduction•Delays(waitingtime)•Transportation•Process•Inventories•Motions•Defectiveproducts•Untappedresources•Misusedresources9WastesTPMtargetsreductionoftheseequipmentorientedwastes10Yesterday:Problem=machinebreakdown=getaroundtheproblemSolution=Workinbatches“Weusethetimeitworkstomassproduce”TPM:ALeanManufacturingMethodTPMandone-pieceflow:Today:Objective=OnepieceflowQualityeverytimeMeans=TPM“Weorganizesoitworkscontinuously”11GoalsofTPMAchievezeroequipmentbreakdownsandzerodefectsthroughprevention.EstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponse12PresentConditionsOperatorsviewmachinesasresponsibleformajorproductionAndlimittheirrolestoequipmentoperationandinspectingforqualityWhilemaintenanceworkersviewtheirfunctionasrespondingtorecurringbreakdowns13MaintenanceApproachesTimeBasedorPlannedMaintenance-Periodicallyscheduledmaintenanceactions.PredictiveMaintenance-Maintenanceactionperformedresultingfromevaluationofequipmentcondition.CorrectiveMaintenance-Maintenanceactionperformedtorestoreoptimalequipmentfunction.PreventiveMaintenance-AcombinationofTimebasedandPredictiveMaintenanceandactionstakentosustainoptimalequipmentperformanceandprecludebreakdowns.14EarlyEquipmentManagementOptimizesequipmentselectionthrough:EquipmentLifeCycleCostAnalysis:analysisofthesumofallcosts(directandindirect)associatedwithanitemofequipmentthroughoutitsperiodofuse.MPDesign:activitywhichisfocusedonminimizingfuturemaintenancecostsandproductionlossesofequipmentatthedesignstage.15TotalProductiveMaintenanceWithoutTPMWithTPMMED&IndustrialEngineeringMaintenanceMED&IndustrialEngineeringOperationMaintenanceTheoperatoroperates,maintenancemaintains,etc.SharedresponsibilitiesOperation16EquipmentMaintenanceResponsibilitiesOperationMaintenanceMED&IndustrialEngineeringAutonomousmaintenanceBreakdownmaintenancePlannedmaintenancePredictivemaintenanceMaintenanceprevention17TotalProductiveMaintenanceTPMEquipmentinbetterworkingconditionDecreaseofbreakdownsDecreaseofin-processadjustmentsOptimizationofoperationspeedManufacturingdefectsLead-timeQualitythefirsttime18PerformanceExcellence:ExpandingtheStrategythroughTPMIntroductionRoleinLeanManufacturingRoleoftheOperatorinTPMAutonomousMaintenanceImplementationEquipmentPerformance:MeasurementandManagement19TotalProductiveMaintenanceTPM,thetotalapproachTheoperatoristhefirstlinecaretakerMaintenancepersonnelarethespecializedcaretakers.20DivisionofMaintenanceDutiesbetweenProductionandMaintenanceDependingonknowledgeandskillsrequired,responsibilityforequipmentmaintenancetasksneedstobedefined:MaintenanceTechnicianProductionOperator*Equipmentoverhaul*Basiclubrication*Specialskilltasks*Generalcleaning*Complexadjustments*Multi-pointinspection*Highsafetyrisktasks*Basicadjustments21MaintenanceTaskAllocationbetweenProductionandMaintenanceMaintenanceTechniciansProductionOperatorsAutonomousmaintenanceimplementationVolumeofmaintenancetasks22PerformanceExcellence:ExpandingtheStrategythroughTPMIntroductionRoleinLeanManufacturingRoleoftheOperatorinTPMAutonomousMaintenanceImplementationEquipmentPerformance:MeasurementandManagement23Autonomousmeans“independent”Autonomousmaintenancereferstoactivitiesinvolvingoperatorsinthemaintenanceoftheirownequipment.AutonomousMaintenance24AutonomousMaintenanceHowtomaketheoperatormoreindependent:Makethedocumentationavailable(manual,maintenanceschedule,logbook).Asateam,definemanufacturing/maintenance/MEDproductivemaintenanceactivities.Showoperatorh