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全员生产保养TotalProductiveMaintenance目录TableofContents一．TPM概略TPMOverview二．TPM目的TheAimofTPM三．TPM流程TPMProcess自主保养AutonomousMaintenance计划保养PlannedMaintenance预防工程PreventiveEngineering教育与行动Education&Practice保证质量InsuredQuality四．TPM改善活动TPMKaizenActivities五．TPM活动进阶AdvancedTPMActivitiesTPM概略TPMOverview何谓TPMWhatisTPM全员生产保养是这样一个系统TotalProductiveMaintenanceisasystemthat涉及工场/维修人员Involvesbothshopfloorassociatesandmaintenanceassociates支持精益西格玛流程SupportstheLeanSigmaProcess保持设备最佳状态Keepsequipmentinoptimalcondition为何要实施TPM？WhyImplementTPM?忽视设备基本状况BasicEquipmentconditionsneglected操作维修技能欠佳Insufficientoperatingandmaintenanceskills设备设计固有不足Inherentweaknessinequipmentdesign设备恶化无人监督Overlookeddeterioration没有遵守使用要求Usageconditionsnotobserved宏观愿景MacroVisionTPM世界性的公司WorldWideCompany工人自主保养OperatorAutonomousMaintenance预防保养PreventiveMaintenance经理支持功能ManagerSupportFunction工程设备设计改善Eng.Equip.DesignImprovement品质改善QualityImprovement全员生产保养TPM高级管理层领导SML生产准备2P西格玛改善SigmaKaizenTPM目标TPMGoals零故障ZeroBreakdowns零缺陷ZeroDefects零事故ZeroAccidents全员参与Totalemployeeinvolvement提高机器效率,满足节拍速度AchieveTaktRateatthehighestmachineeffectivenessTPM与精益西格玛流程TPMandLeanSigmaProcessFLE及时生产JustinTime自働化Jidoka均衡生产ProductionSmoothing机器可靠MachineReliability机器高效MachineEffectiveness联动操作LinkedOperations人力利用LaborUtilization制程能力ProcessCapability最佳机况Optimalmachineconditions制程重复ProcessRepeatability防错装置MistakeProofing实现流畅生产,必须实行TPMTPMisessentialwhenflowproductionisachievedTPM与传统保养TPMvs.TraditionalMaintenance每班8小时8hrshift有效时间=7小时40分Effectiveness=7hrs40min工人开会:10分钟OperatorMeeting10min10min设备清洁与润滑:10分钟Equipmentcleaning&Lubrication传统生产班次TraditionalOperatingShift:实行TPM的班次TPMShift:本班开始ShiftStart品质问题Quality暂停MinorStoppages故障停机Breakdown调整Adjustment本班结束ShiftEnd每班8小时8hrshift有效时间=6小时Effectiveness=6hrs整体设备效率OverallEquipmentEffectiveness故障停机Breakdowns换模Set-ups调整Adjustments空闲Idling暂停MinorStops速度降低ReducedSpeed不良品Defects返工Rework启动Start-up合格率损失YieldLossAvailability=Performance=Quality=AvailableTime–DowntimeAvailableTimeMCTX#PartsProducedOperatingTime#ofPartsProduced–Defects/Rework#ofPartsProduced六个主要损失SixMajorLosses整体设备效率%=可用效率x性能效率x品质效率x100%OEE(%)=AvailabilityXPerformanceXQualityX100%DiscreteMfg.ProcessInd.AvailableTime–DowntimeAvailableTimeAmountProducedStd/hrXOperatingTime(hrs)Amount–Defect/ReworkTotalAmountProduced可用效率性能效率质量效率可用时间–停机时间可用时间操作时间机器周期时间X已生产零件数已生产零件数–不良品数/返工数已生产零件数离散式生产流程工业可用时间–停机时间可用时间标准产值/小时x操作时间已生产产值总产值–不良品/返工产值已生产总产值EquipmentUtilization(availability)(whendoyouPLANTorunit?)MaximumPossibleProduction=1440minutes(24hours)PlannedDowntimeNo3rdshift=420Min.Lunch(2shifts)=60Min.Dept.Meetings=20Min.PlannedDowntime=500Min.ThisiswhereOEEStarts!MaxPossibleProduct1440Min.PlannedDowntime-500Min.ScheduledProduction=940Min.MaxPossibleProductionScheduledProductionAvailabilityCanyourunitwhenit’sscheduled?940Min.ScheduledProduction-150Min.Setup790Min.-140Min.Breakdowns650Min.ScheduledProductionMaxPossibleProductionPerformanceEfficiencyHowfastdoyourunwhenyourun?650Min.185Min.MinorStoppagesJamsNoPartsNoBoxes-40Min.SpeedLoss-ScheduledProductionMaxPossibleProductionActualProduction465Min.=425Min.ActualProductionRateofQuality…HowmuchofwhatyoumakeIsthecustomerhappywith?425Min.ActualProduction-51Min.TimeUsedManufacturingDefectiveParts374Min.GoodProductScheduledProductionMaxPossibleProductionActualProductionGoodProductionOverallEquipmentEffectivenessGoodProductionScheduledProductionOEE==39.8%OEE=374940ScheduledProductionMaxPossibleProductionActualProductionGoodProductionGoodProductionMaximumPossibleProductionTEEP=TotalEffectiveEquipmentProductivity量度指标Metrics整体设备效率OverallEquipmentEffectiveness(OEE)可用效率Availability性能效率Performance品质效率Quality保养效率MaintenanceEffectiveness平均故障时间间隔MTTF(Meantimetofailure)平均无故障时间MTBF(Meantimebetweenfailure)平均维修时间MTTR(Meantimetorepair)可靠性ReliabilityMTTRMTBFMTBF时间Time性能PerformanceLevel最差状况MinimumConditionMTTF理想状况IdealConditionMTTF=平均故障时间间隔:上次故障至本次故障之时间MeantimetoFailure(thetimefromthepreviousbreakdowntothecurrentbreakdownofmachine.MTBF=平均无故障时间:从开机到故障停机之时间Meantimebetweenfailure(theelapsetimefromthestartupofthemachinetothecurrentbreakdownofthemachineMTTR=平均维修时间:从上次故障停机到重新开机之时间thetimefromthepreviousbreakdowntostartupofthemachine.保养效率由MTBF及MTTF来衡量,比例越高,机况越好!MaintenanceeffectivenessismeasuredbyMTBF/MTTFThegreaterthepercentagethebetter!TPM的目的：TheAimofTPM:改善设备运行状况Toimprovetheequipmentoperatingcondition维持设备最佳性能与可靠性Tosustainequipmentatanoptimallevelofperformance&reliability延长设备使用寿命TolengthenthelifeexpectancyofequipmentTPM流程TPMProcessTPM五大支柱The5PillarsofTPM自主保养AutonomousMaintenance计划保养PlanningMaintenance预防工程PreventiveEngineering品质Quality教育与行动Education&Practice实施TPM十步骤TPMImplementation-10Steps1.测量工作单元上所有自动设备之OEEMeasureOEEforallautomaticequipmentincells.2.测量各工作单元的节拍时间MeasureTaktrateperformanceforeacharea.3.将单元节拍时间与设备OEE进行比较CorrelatecelltaktrateperformancetoequipmentOEE.4.选择特定机器作为改善重点Selectspecificmachineforkaizenfocus.5.根据OEE六大损失制定改善目标EstablishimprovementgoalrelatedtothesixmajorlossesofOEE.6.选定设备改善专职队员Selectpermanentequipmentimprovementteammembers.7.发动工人进行自主保养及计划保养活动Initiateop