1、1 ProcessCertificationTPMQCPCRoot Cause /CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinic ActivityTotal Productive Maintenance ACE Manufacturing Qualifying Level 2 程序验证程序验证全面性生产全面性生产维护维护质量诊断程序质量诊断程序图表图表根本原因根本原因修正行动修正行动减少生产减少生产准备准备标准化标准化作业作业防误措施防误措施市场反馈市
2、场反馈分析分析6S质量诊断质量诊断行动行动全面生产性维护 ACE 生产部门合格水平 3Total Productive Maintenance is an equipment management strategy that improves equipment efficiency.全面生产性维护是一种设备管理策略以提高设备效率。Or, in other words.Treating the equipment like it is your own!或者，换句话说.对待设备就象它是你自己的一样！TPM 全面生产性维护4TPM Key Concept TPM的重要概念 Left neglec
3、ted. Equipment Breaks Down 如果不重视设备很快就会坏TPMs focus is to prevent problems before equipment breaks.TPM 的焦点是要在设备出故障以前以前防止问题出现。In the past, maintenance focusedon fixing equipment after it broke.过去，维护工作总是集中在设备坏了以后对其进行修理。5Total Productive Maintenance is a New Way of Working全面生产性维护是一种全新的工作方式全面生产性维护是一种全新的工作
4、方式6Hidden Defects隐藏的问题隐藏的问题Failures故障故障Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw materials,surface damage, cracking, overheating, vibration, noise, and other abnormalities.磨损、松驰、泄露、灰尘、污垢、腐蚀变磨损、松驰、泄露、灰尘、污垢、腐蚀变形、原材料粘黏、表面磨损、裂缝、过热形、原材料粘黏、表面磨损、裂缝、过热、震动、噪音及其它不正常现
5、象。、震动、噪音及其它不正常现象。Tip of the Iceberg冰山的顶端7Typical Causes of Machine Breakdown 典型的机械故障原因Failure toadd oil.没有加油Grit and chipsin revolvingor sliding parts旋转或滑动零件中的砂砾和碎片Contaminationof sensors,contacts and Connectors传感器、触敏器、连接器污染Dirt and dust on cooling fan冷却风扇上有灰尘和污垢ComponentFailure组件失灵I wonder whatsgoi
6、ng to fail next?我在想下面还会出什么我在想下面还会出什么问题呢？问题呢？8TPM Techniques TPM技术Normal operating Range正常操作范围正常操作范围Danger!危险！危险！ Simplify and Document TPM Activities. 简化并记录TPM行动 Use visual techniques to indicate whats right / whats wrong. 运用直观技术来演示什么是 对的/什么是错的。PM Completed? 生产性维护完成了吗？Pressure gage 压力计Sight glass 视镜
7、Arrows for motor rotation and fluid circulation马达旋转和润油指示箭头markings for spare parts and fluids. 备用零件和润滑油记号Making PM devices more accessible. 使生产性维护设备更容易获得 Filters, fittings made more accessible 过滤器、各种装置Transparent panels to facilitate inspection 明了易读的仪表盘便于检查9TPM Benefits TPM的益处 Reduced maintenance co
8、sts 减少维护费用 Breakdown maintenance is 10 times more costly than planned maintenance 故障维修费用是有计划进行维护费用的10倍以上 Enhanced safety 提高安全性 Find exposed wires, open belts, missing guards, loose hardware 发现暴露在外的电线、松开的安全带、缺少防护、松开的部件 Reduced waste 减少浪费 Prevents loss of lubricant, compressed air 防止润滑油、压缩空气的浪费 Improv
9、ed quality 提高品质 Equipment more capable of holding tolerance 设备抗性增强 Less down time, longer life缩短停工时间，寿命更长1012 TPM Qualifying ActivitiesACE Element Awareness TrainingLock Out/Tag Out awareness training available for all employees (with annual refresher)Operators of high hazard equipment informed of m
10、achine specific hazardsAssessment of machine specific safeguarding (SP-008) issuesLock Out/Tag Out Equipment AvailableReview OnlyAction ItemsAssess all Equipment A, B & CImplement written Lock Out/Tag Out procedureWalk around safety check on 100% of A/B equipmentPM Schedule for 100% of A/B equipment
11、Cleaning on 100% of A/B equipmentTrack downtime historyTop ten downtime equipment identified1112 项TPM 合格行动ACE 内容认知培训锁定/标识 认知培训，针对所有员工（每年的复习进修者）告知高危险设备操作员有关机器的详细危险机器的特殊防护措施（SP-008）问题评估可用的锁定/标识设备仅用于检查行动内容评估所有 A, B & C类设备完成写好的锁定/ 标识程序所有 A/B类设备的安全巡查所有 A/B类设备的生产性维护进度表清洁所有A/B类设备追溯停工历史确认的十大停工设备12PURPOSE of
12、 Lockout/Tagout锁定锁定/标识的目的标识的目的Lockout/Tagout Review:锁定锁定/标识检查标识检查13Lockout Device 锁定设备A lock or other device that utilizes a positive means, to hold an energy isolating device in a safe position and thereby preventing the energizing of a machine or piece of equipment.一把锁或其它设备，用于使电源设备隔离装置处于一安全的状态，以防止
13、机器或设备的一部分带电。Lockout/Tagout Review:锁定锁定/标识检查标识检查14Tagout Definition 标识的定义 The process of securely fastening a tag or prominent warning sign to indicate that both the energy isolating device and the equipment being controlled, be operated. 是将一标签或明显的警告标志紧附于设备上 以表明不能不能对电源隔离设备及处于控制下的 设备进行操作。 The tag will
14、 also include the name of the person who locked out the equipment.该标签应有锁定该装置的 人的名字。Lockout/Tagout Review:锁定锁定/标识检查标识检查15NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.决不要从它人处接受锁定设备的钥匙。决不要从它人处接受锁定设备的钥匙。THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOCK OR
15、TAG.唯唯有经授权负责运用锁或标签的人员可以拿掉该锁或标签。有经授权负责运用锁或标签的人员可以拿掉该锁或标签。Lockout/Tagout Review:锁定锁定/标识检查标识检查16ACTION ITEM 1: Assess All Equipment行动内容行动内容1：评估所有设备：评估所有设备 By “Equipment” we mean any machine that was a capital expense and has a depreciative value. Or any machine that is important to your cell. 所谓“设备”是指任
16、何花费了资金并会贬值的机器。或任何对你的部门重要的机器。We Categorize all Equipment based on how Unique and Critical it is to ensure we focus attention on the right equipment first. Pay special attention to bottleneck equipment.我们根据设备的独特性和重要性对所有设备进行分类，以确保我们的注意力优先放在正确的设备上。对瓶颈设备给予特殊的关注。Equipment设备设备17 Critical equipment for whic
17、h an alternate machine is not feasible, because:不能用其它设备替代的关键设备，因为： No alternate exists, or 无替代设备，或 The alternate is usually unavailable due to utilization, or 该替代设备通常正被使用而不能获得，或 It would be too costly/time consuming to transition to the alternate 太贵/需花太多时间进行替换 Equipment for which it is relatively ea
18、sy to find a replacement or alternate相对容易用其它设备替代的设备 Includes most off-the-shelf equipment 包括最常用的设备 Typically cost $2,500 费用低于$2,500 Standard spare parts (like drive motors) are available off-the-shelf 可获得的常用标准备件（如驱动马达） All other equipment/machines所有其它设备/机器ACTION ITEM 1: Assess All Equipment (cont.)行
19、动内容行动内容1：评估所有设备（待续）：评估所有设备（待续）18In addition to machine category, create a table listing all machines and additional categories, such as: 除了机器分类，还应作一表格列出所有机器和附加类别，如：Year of manufacture产品的生产年份Type of machine? Condition? (Good / Fair / Poor)机器类型？状况？（好/一般/差）Does Operator PM process exists (Has a service
20、 card been created?)是否有操作员生产性维护程序（是否有服务卡？）Does Maintenance PM process exist (Does a written maintenance task list exist?)是否有维护生产性维护程序（是否有记录的维护任务表？）Has the machine undergone initial cleaning?机器是否经过最初的清洁？Has machine been assessed for safeguarding per SP008? (EH&S items)机器是否经过安全装置SP008评估？（EH&S项）ACTION
21、ITEM 1: Assess All Equipment (cont.)行动内容行动内容1：评估所有设备（待续）：评估所有设备（待续）MACHININGSafety Plan - 2000AREA: 007MACHINE CATAGORYBRASS TAGYEARTYPE EQUIPGEN. COND. GOOD/FAIR/ POORB312488BridgeportGoodB300485HardingeGoodBE1507558Warren Spin PitPoorBE6049187Shadow graphGoodBE7631291Balance controllerGoodB316890B
22、ostoGoodB261578BostoGoodB254875LapperGoodB328093OkumaGoodB319891Harrison man. latheGood19Possible Categories:可能的分类： Equipment which retains all of its original functions, accuracy and reliability. ：设备保持所有原来的功能，精确并可靠。 Equipment which has lost some of its original functions or accuracy. Its output nor
23、mally meets the required specifications.：设备丧失了一些最初的功能或精确度。其产品符合要求的规范。 Equipment which is no longer accurate or reliable. In order to produce acceptable output, this equipment requires operator intervention well beyond the original level. 设备不再精确或可靠。为了生产出可接受的产品，要求操作员对设备进行超出原有水平的干涉。ACTION ITEM 1: Asses
24、s All Equipment (cont.)行动内容行动内容1：评估所有设备（待续）：评估所有设备（待续）20ACTION ITEM 2: Write Machine-Specific Lockout ProceduresLockout procedures must be written and implemented for each machine General procedures are in effect for Sullair Procedures need to be written jointly with facilities maintenance21行动内容 2:
25、将特殊锁定程序写在机器上锁定程序必须写在每台机器上并予以执行 一般程序适用于寿力公司 程序必须与设备维护 共同写下来22 ACTION ITEM 3/4: Operator Walkaround and PM Schedule on 100% A/BOperator PM defined for 100% of Category A and B machines A book or sheet exists which defines the daily/weekly/monthly Operator PM tasks Include safety equipment operation (g
26、uards, limit switches, etc.) in Operator PM.Operator PM conducted faithfully (1 month prior to audit) on all Equipment for which it is defined.Rev: BRevision Date: 3/ 25/98Operator Preventive Maintenance Service CardMachine: Okuma LC-30, 4 Axis, BT # 3054Daily PM Tasks1. Check running sight.2. Check
27、 and fill Waylube: Vactra 2.3. Check tramp oil and scrounger. Empty tramp oil if required.4. Check and fill coolant: PML 9333.Weekly PM Tasks: Do Daily tasks and the following:1. Check and fill spindle lube: DTE 24.2. Check and fill air lubricator: DTE 24. (Shut off and drain air to fill)3. Check mo
28、tor fan filter (Change if necessary): Cat. # 030058.4. Check and fill hydraulic tank: DTE 24.5. Check roll filter (Change if needed): Cat. # 027793.Monthly PM Tasks: Do all tasks on this sheet.1. Grease chuck fittings, 1 shot.2. Grease 1 fitting, 2 shots, both turrets.3. Clean air filter.4. Change a
29、ir filter: Cat. # 021183.23 行动内容 3/4: 操作员巡查和操作员巡查和 所有所有 A/B类设备的类设备的PM进度表进度表操作员PM定义为所有A、B类机器 应有写明了操作员每日/周/月的PM任务的书或表 包括安全设备（防护装置、限定电闸等）操作员严格地按要求对所有设备进行生产性维护（在审查前一个月）Rev: BRevision Date: 3/ 25/98Operator Preventive Maintenance Service CardMachine: Okuma LC-30, 4 Axis, BT # 3054Daily PM Tasks1. Check r
30、unning sight.2. Check and fill Waylube: Vactra 2.3. Check tramp oil and scrounger. Empty tramp oil if required.4. Check and fill coolant: PML 9333.Weekly PM Tasks: Do Daily tasks and the following:1. Check and fill spindle lube: DTE 24.2. Check and fill air lubricator: DTE 24. (Shut off and drain ai
31、r to fill)3. Check motor fan filter (Change if necessary): Cat. # 030058.4. Check and fill hydraulic tank: DTE 24.5. Check roll filter (Change if needed): Cat. # 027793.Monthly PM Tasks: Do all tasks on this sheet.1. Grease chuck fittings, 1 shot.2. Grease 1 fitting, 2 shots, both turrets.3. Clean a
32、ir filter.4. Change air filter: Cat. # 021183.24Make Operator PM effective:Use a “Visible at-a-glance” system (Such as a color-coded PM Status board) within the cell to indicate the actual status of “Operator PM” tasks. Must be easy to understand No book or folder to read ACTION ITEM 3/4: Operator W
33、alk around and PM Schedule on 100% A/B (cont.)AREA:_ - OPERATOR PM STATUS BOARDMonth:_Required PMsDateMachine NameBrass Tag #DailyWeeklyMonthly12345678910Daily = Task #1in PM LogsWeekly = Task #2 in PM Logs (to be done every Wednesday)Monthly = Task #3 in PM Logs (to be performed every 2nd Wednesday
34、 of the month)Machine Not Operated or PM Not RequiredEquipment Breakdown25使操作员进行有效的生产性维护:使用一眼就能看见的系统 (如使用颜色代码PM状态板) 在单元中表明“操作员PM”任务的实际状态 必须容易理解 无需翻书或文件夹行动内容 3/4: 操作员巡查和操作员巡查和 所有所有 A/B类设备的类设备的PM进度表进度表（待续）（待续）AREA:_ - OPERATOR PM STATUS BOARDMonth:_Required PMsDateMachine NameBrass Tag #DailyWeeklyMon
35、thly12345678910Daily = Task #1in PM LogsWeekly = Task #2 in PM Logs (to be done every Wednesday)Monthly = Task #3 in PM Logs (to be performed every 2nd Wednesday of the month)Machine Not Operated or PM Not RequiredEquipment Breakdown26Cosmetic Cleaning禁止化装品禁止化装品ACTION ITEM 5: Initial Inspect/Clean 1
36、00% A/B行动内容 5：初步检查/清洁所有A/B类设备27 Accessible components cleaned, inspected and repaired 可用的部件已清洁、检查和修好 PM documentation is reviewed/updated PM文件已检查/更新 Basic improvements are incorporated to improve maintainability and visual 基本的改进用于提高可维护性和形象 operating condition 操作环境How about that. I didnt even know th
37、ere was a grease fitting here!那个怎么样。我甚至不那个怎么样。我甚至不知道这儿还有个油脂知道这儿还有个油脂装置！装置！ACTION ITEM 5: Initial Inspect/Cleaning 100% A/B (Cont.)行动内容 5：初步检查/清洁所有A/B类设备（待续）28Use downtime tracking results to determine the top ten downtime equipment.根据停工追溯结果来决定十大停工设备ACTION ITEM 7: Top Ten Downtime行动内容行动内容 7：十大停工设备：十大
38、停工设备Pareto ChartPareto 图表29What is next?下一步是什么？Complete TPM training of your work group by March 7, 20012001年3月7日前你的工作组应完成TPM培训Before the end of February, look for a groupwiseannouncement of a “Drivers” Meeting to discussthe necessary resources and logistics for completingqualifying TPM activities在2
39、月底以前，宣布召开“领导层”会议，讨论必要的资源和后勤以帮助完成取得合格资格的TPM行动30We want a company that reveres people who design, build and maintain things that never break, rather than people who fix things that break. George DavidUTC Chairman and CEO我们希望公司尊敬那些设计、建造并维持不会坏我们希望公司尊敬那些设计、建造并维持不会坏的东西的人们，而不是那些修理会坏的东西的人们。的东西的人们，而不是那些修理会坏的东西的人们。 George DavidUTC Chairman and CEOSummary 小结31Total Productive Maintenance全面生产性维护Manufacturing生产部
