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TotalProductiveMaintenance全员生产保全TotalProductiveMaintenance全员生产保全MeaningofTPM全员生产保全之意义AJapaneseKaizenStrategyfocusonimprovingtheefficiencyofmachinetogaintheoverallprofitofthecompany.为日本的改善策略活动之一种，着眼于改进机器设备的效率，以提升公司整体的利益。TotalProductiveMaintenance全员生产保全FeaturesofTPMTPM之特徵Emphasizeoverallcompanyefficiency着重企业整体的效率化AchieveZeroDefect,ZeroAccident,ZeroShutdown追求零不良、零灾害、零故障Involvealldepartments,Production,R&D,Marketing包含所有部门，生产、开发、营业部门Allemployeesparticipation,fromCEOtooperator从总经理到作业员均参与KaizenbySmallGroupActivities以小团队活动来进行改善TotalProductiveMaintenance全员生产保全BenefitsofimplementingTPMTPM之目的Reduceshutdowntimetodeliverproductontime减少停机，交期准时StabilizeMachineCapabilitytoassurequalitylevel稳定性能，确保质量IncreaseOverallEquipmentEfficiencytoreducecost提升效率，降低成本Upgradeoperationskillstoguaranteesafety提升技能，保证安全TotalProductiveMaintenance全员生产保全LevelofMaintenance保全的境界BM:BreakdownMaintenance事后保全PM:PreventiveMaintenance预防保全CM:CorrectiveMaintenance改良保全MP:MaintenancePrevention保全预防TotalProductiveMaintenance全员生产保全6PillarsofTPMTPM六大支柱User’sMaintenance自主保全PlannedMaintenance计划保全CaseCorrection个别改善InitialManagement初期管理EasierManufacturing易制设计EducationTraining教育训练TotalProductiveMaintenance全员生产保全RelationshipbetweenPillarsandLevels支柱与境界之关连Breakdown事后Maintenance保全User’sMaintenance自主保全PlannedMaintenance计划保全CaseCorrection个别改善EducationTraining教育训练InitialManagement初期管理EasierManufacturing易制设计Preventive预防Maintenance保全Corrective改良Maintenance保全Maintenance保全Prevention预防TotalProductiveMaintenance全员生产保全6MajorLossesofMachine设备六大损失EquipmentBreakdown故障损失MinorStoppage瞬停损失Changeover/Adjustment换模损失Defects/Rework不良损失SpeedReduction退化损失WaitingOperation等待损失TotalProductiveMaintenance全员生产保全RelationshipamongLosses,PillarsandJobFunction(1/2)损失、支柱与职务之关连(1/2)Losses损失Pillars支柱EquipmentBreakdown故障损失User’sMaintenance自主保全PlannedMaintenance计划保全CaseCorrection个别改善EducationTraining教育训练InitialManagement初期管理EasierManufacturing易制设计MinorStoppage瞬停损失ChangeoverAdjustment换模损失DefectRework不良损失SpeedReduction退化损失WaitingOperation等待损失TotalProductiveMaintenance全员生产保全RelationshipamongLosses,PillarsandJobFunction(2/2)损失、支柱与职务之关连(2/2)Pillars支柱Job职务User’sMaintenance自主保全Operator作业员Supervisor线长MaintenanceTechnician保全员Consultant顾问MaintenanceEngineer工程师DevelopEngineer开发PlannedMaintenance计划保全CaseCorrection个别改善EasierManufacturing易制设计InitialManagement初期管理EducationTraining教育训练TotalProductiveMaintenance全员生产保全MeasuresforEquipment设备绩效衡量指标OverallEquipmentEfficiency设备总合效率(可动率)Measureoftheavailable,performanceandqualityefficiencyofequipment衡量设备的时间、性能及质量之效率MeanTimeBetweenFailures平均故障间隔时间MeanFrequencyOfFailure平均故障次数Measureofthereliabilityofequipment衡量设备的可靠能力MeanTimeToRepair平均修护时间Measureofthemaintainabilityofequipment衡量设备的维修能力TotalProductiveMaintenance全员生产保全DefinitionofOEE(1/2)设备总合效率之定义OEE可动率=EquipmentAvailableEfficiency设备时间效率xPerformanceEfficiency性能效率xQualityEfficiency质量效率EquipmentAvailableEfficiency设备时间效率:•Lossofbreakdown故障损失•Lossofchangeover换模损失•Lossofinspection检查损失•Lossofwaiting等待损失TotalProductiveMaintenance全员生产保全DefinitionofOEE(2/2)设备总合效率之定义PerformanceEfficiency性能效率:Lossofminorstoppage瞬停损失Lossofdummyrunning空转损失Lossofspeedreducing退化损失QualityEfficiency质量效率:•Lossofdefects不良损失•Lossofrework重修损失•Lossofretest重测损失TotalProductiveMaintenance全员生产保全CalculationofOEE可动率的算法(1/2)(A)TotalTimeaday每日时间=60min分x24Hrs小时=1440min分(B)PlannedShutdownTime计划停机时间=480min分b1)BreakTime休息时间=60min分x2=120min分b2)PreventiveMaintenance预防保全时间=60min分x2=120min分b3)NoOrderWaitingTime无定单等待时间=60min分x4=240min分(C)ProductionScheduledTime生产计划时间(=A-B)=960min分(D)UnscheduledDownTime意外停止时间=100min分d1)Breakdown故障=20min分d2)Changeover/Setup/Adjustment换模/安装/调整=40min分d3)ToolsChange/Inspection刀具更换/检查=30min分d4)WaitingOperator/Materials等待人员/材料=10min分TotalProductiveMaintenance全员生产保全CalculationofOEE可动率的算法(2/2)(E)AvailableOperationTime有效生产时间(=C-D)=860min分(F)EquipmentAvailableEfficiency设备时间效率(=E/C=860/960)=89.6%(G)TotalOutputQuantity全部生产数量(=1450pcs个)(H)IdealCycleTime理论周期时间(=0.5min分/pc个)(I)EquipmentPerformance/Efficiency设备性能效率｛=(GxH)/E｝=84.3%(J)TotalRejectedQuantity总不良数=200pcs个(K)EquipmentQualityEfficiency設備品質效率｛=(G-J)/G｝=86.2%(J)OEE可动率=FxIxK=89.6%x84.3%x86.2%=65.1%or或者=(G-J)xH/C=65.1%TotalProductiveMaintenance全员生产保全WhatisUser’sMaintenance何谓自主保全Theuserofequipmentisresponsibleforsomebasicmaintenanceactivitiesofequipment由使用机器设备的操作者，负责从事一些机器设备的基本保全工作之意。TotalProductiveMaintenance全员生产保全ObjectivesofUser’sMaintenance自主保全之目的Increasetheuser’scareonequipment.提升操作者对设备的关心度Increasetheuser’scapabilitytooperateequipment提升操作者对设备的操作能力Increasetheuser’scapabilitytofindouttheabnormalsituationofequipmentearlier.提升操作者能早期发觉设备异常状况之能力ToincreasethereliabilityandOEEofequipment.提升设备的可靠能力及提升设备的可动率TotalProductiveMaintenance全员生产保全SevenStepsofUser’sMaintenance自主保全展开七步骤1)Initialcleaningandcheck初期清扫点检2)Eliminationofsourcesofcontamination排除困难发生源头3)Establishstandardsofcleaningandlubrication作成清扫及润滑基准4)Implementgeneralinspectionandtraining实施总点检及技能教育5)Implementinspectionbyuser实施自主点检6)Implementqualityassurance实施质量保证7)Maintainstandardsandcontinueimprovement自主维持管理及提升水平Purpose目的Learntheteamworkactivitiesandleadershipskills学