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1TotalProductiveMaintenance全生产性维护2Motto:withTPMthemachinesrun,nottheemployees是TPM,而不是人在维持机器运行3BeforeTPMimplementation..实施TPM前.…after实施后PracticingTPMmeansanattitudechange实施TPM意味着态度的改变SourceC.M.B我的工作是清洁我的工作是阻止漏油等4TopracticeTPMmeanstochangetheoperatorrole.实施TPM意味着改变操作工的角色SourceC.M.BBeforeTPMimplementation…实施前…after实施后我的工作是拣起瓶子我的工作是不让瓶子掉下来56789HowDoesTPMDifferFromRegularMaintenance?TPM与日常维护有什么差别zItisaproactive,teamapproachformaintenance它是前瞻性的团队维护zItistheresponsibilityofeveryone,notjustthemaintenancedepartment它是每个人的职责,而不仅仅是维修人员的职责zEnsuressafetyandeffectiveoperationofequipment确保设备的安全及有效运行zKeepsequipmentfrombreakingdown让设备不要有故障zPlannedrepairsratherplannedfailure有计划的维修而不是有记号的故障zPreventsdeteriorationandprolongsthelifecycleoftheequipment预防设备渐渐地出现问题,延长其寿命周期10TheAdvantagesofTPMTPM的好处•Typicalcapacityincreasefrom30-40%能提高能力30-40%•Teamworkbetweenproductionandmaintenance生产与维护间的团队合作•Makespossiblealongtermrealismof„zerodefects“-scrap,defects,safety使长期”零缺陷“成为可能•Makespossiblealeanproduction是精益生产成为可能•Makesacompetitiveadvantageinproduction-costs,delivery,quality,moral(OEE,maintenancecapability)使生产具有竞争优势-成本,质量,生产率11ThegoalistogettoScheduledMaintenance目标是要达到计划性维修Intermediate中级阶段BreakdownMaintenance停工维修MaintenancePrevention避免维修CorrectiveMaintenance设备保养PreventiveMaintenance预防性维修Reactive反应性维修Beginning初级阶段ScheduledMaintenance计划性维修Advanced高级阶段Predictive预见性维修StagesofMaintenance维修的阶段Copyright1998byLeanAlliance12FirstSteps….第一步PreventiveMaintenance-Preventingbreakdownsfromoccurringthrougharegularmaintenanceprogramthatfillsfluidlevels,replacefilters,…预防性维护-通过定期维护计划来防止故障发生,比如:加油,换过滤器等CorrectiveMaintenance-MakingPreventiveMaintenanceeasierintheorsettinguptheequipmenttopreventabreakdown.纠正性维修-使预防性维护更加容易,或调整设备防止故障BreakdownMaintenance-Areviewofmachinedowntimedatathatanalyzesthecausesandputsaplaninplacethatwillreducetheamountoftimeittakestorepairamachineafterabreakdown.故障维修-研究停机时间,时间分析原因,并实施计划,这样可在发生故障后花较少的时间来修复MaintenancePrevention-Buyingordesigningyourequipmentsothatitneedsminimalmaintenance.安全措施-购买或设计需要最少维修的设备TPMTPMincorporatesandplansforthefollowingareas:以下领域内的TPM组合与计划Copyright1998byLeanAlliance13Advancedsteps…高级阶段•Predictivemaintenance-usingtechnologytopredictmachinefailure.Heatanalysis,vibration,electricalcurrent,……..预见性维修-运用技术来预见故障.热分析,振动,电流•Scheduledmaintenance-usingthedatafromthepreviousprograms(preventive,……,predictive)toregularlyschedulemachinedowntimewiththeproductiondepartment.Thisplanneddowntimeallowsmaintenanceandproductiontoworkintrueharmony.计划性维修-运用以前的数据来计划机器的定期停机.计划好的停机时间内可进行维修,并使生产得到协调ForacelltohaveanychanceofbeingLean,allthemachinesneedtohavepredictablehighlevelsofuptime要达到精益生产的标准,所有的机器都要达到可预见的较高运行水准TPMCopyright1998byLeanAlliance14Copyright1998byLeanAllianceThegoalistogettoScheduledMaintenance目标是要达到计划性维修Intermediate中级阶段BreakdownMaintenance停工维修MaintenancePrevention安全措施CorrectiveMaintenance设备保养Reactive反应性维修Beginning初级阶段ScheduledMaintenance计划性维修Advanced高级阶段Predictive预见性维修StagesofMaintenance维修的阶段PreventiveMaintenance预防性维修15PreventiveMaintenance预防性维修zPMisaprogramthathasregularrequiredmaintenanceforaparticularmachinepreferablybythemachineoperator.(cleaning,greasing,etc)Thegoalofthisprogramistoensurelittletonodowntime.预防性维修是这样一套程序,它需要由操作者对机器进行定期的维护.•Theprogrammeshouldatthebeginningcollectandevaluatedata:这套程序需要在初级阶段收集并评估数据–fromthemaintenancebookofthemachine来自机器的维修手册–theperformanceofthemachine(shouldbe)机器的性能–Informationfromthemachineoperator来自操作工的信息–frommaintenancepersonnel/personnelfromthearea来自维修人员/现场人员–aboutbreakdowns,stopsetc关于故障,停机等Copyright1998byLeanAlliance16restoration恢复Degradation退化originalcondition原状Maintenance维修Improvement改进Restoresthemachinetoitsoriginalcondition将机器恢复到原状SourceCMB17Restoration修补•InspectionI检查I-Abnormalityidentification确认异常状况-audit审核-tagging挂标签-photographs拍照片•InspectionII-Cleaning检查II-清洁•InspectionIII-Machinerun检查III-机器运转•repairabnormalities修复异常•planfurtherimprovements计划进一步改进Improvement改进•Settargets(OEE85%)设定目标(OEE85%)•Understandcurrentsituation了解现状-Collectdata收集数据-Paretolosses用Pareto分析损失•SetImprovementPlan设定改进计划-What?How?Where?Who?When?5W-Problemsolving解决问题Maintenance维护•Standardisation标准化-Cleaning清洁-Lubrication润滑-Equipmentinspection检查设备•TrainingPlan培训计划PDCAThereare3Stages3个阶段18INTRODUCTION导入Step1Managementdecision管理决定Step2Communicationandmanagementtraining沟通与管理培训Step3TPMcouncilimplementation成立TPM委员会Step4Baselineanalysis现状分析Step5Designofaprogram设计程序DEVELOPMENT发展Step6Kickoff开始Step7Analysisandeliminationofmajordisorders分析并消除主要问题Step8Autonomousmaintenancedevelopment发展自治性维修Step9Planned-preventative-maintenancedevelopment发展计划性,预防性维修IMPLEMENTALONGLASTINGPROCESS执行一个持久的程序Step10Improveemployeescompetency(training)增强员工竞争力(培训)Step11Implementafeedbackloopinequipmentdesign在设计设备时实施反馈循环Step12QuestforaTotalQualityaward(Deming)追求全面质量奖The3Phase-12(?)StepprocesstoimplementT.P.M.(Nakajimabasicprocess)3阶段-实施TPM的12个步骤19InitialCleaningChecklist-AuditMachineNumber:..................Date...................Shift:.................Page1of2CategoryItemstocheckPointsEvaluationCriteriaPtsscoredLowMediumHighCleaningofMainBodyofthemachine1.