一份老外的TPM讲义

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1、1A STRATEGY FORPERFORMANCE EXCELLENCE2Performance Excellence SeriesTraining Module ElementsExecutive OverviewParticipant manualTools WorkbookKnowledge BreakthroughLecture notesLecture notes3Table of ContentsExecutive OverviewSession 1.0Introduction.3Session 2.0Role in Lean Manufacturing.8Session 3.0

2、Role of the Operator in TPM.18Session 4.0Autonomous Maintenance Implementation22Session 5.0Equipment Performance:Measurement&Management.564Total Productive MaintenanceDo these problems sound familiar?nEquipment is always breaking downnOperating machines at rated speeds creates defectsnSetups and adj

3、ustments take too longnMinor machine stoppages are eroding productivity5Total Productive MaintenanceA series of methods to ensure that process machines are always able to perform their functions so that production is never interrupted.6Total Productive MaintenanceWhat it is:1.Optimizes equipment eff

4、iciency2.Implements a company wide Preventive Maintenance system3.Involves production equipment designers,operators,and maintenance department personnel4.Involvement from Management down to floor workers5.Implemented through small,self directed team activities7Total Productive MaintenanceTypical suc

5、cess results after implementation of TPM:Breakdowns:1/30 to 1/100 of prior levelMachine defects:1/30 to 1/40 of prior levelProductivity:30-100 percent increasesource:K.Shirose,TPM For Workshop Leaders,p.108Performance Excellence:Expanding the Strategy through TPMIntroductionRole in Lean Manufacturin

6、gRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management9The Nine types of waste Overproduction Delays(waiting time)Transportation Process Inventories Motions Defective products Untapped resources Misused resources 9 WastesTPM targets reductio

7、n of these equipment oriented wastes10Yesterday:Problem=machine breakdown =get around the problemSolution=Work in batches“We use the time it works to mass produce”TPM:A Lean Manufacturing MethodTPM and one-piece flow:Today:Objective=One piece flow Quality every timeMeans=TPM“We organize so it works

8、continuously”11Goals of TPMnAchieve zero equipment breakdowns and zero defects through prevention.nEstablish prevention by Maintaining normal conditions Early detection of abnormalities Quick response 12Present ConditionsnOperators view machines as responsible for major productionnAnd limit their ro

9、les to equipment operation and inspecting for qualitynWhile maintenance workers view their function as responding to recurring breakdowns 13Maintenance ApproachesTime Based or Planned Maintenance-Periodically scheduled maintenance actions.Predictive Maintenance-Maintenance action performed resulting

10、 from evaluation of equipment condition.Corrective Maintenance-Maintenance action performed to restore optimal equipment function.Preventive Maintenance-A combination of Time based and Predictive Maintenance and actions taken to sustain optimal equipment performance and preclude breakdowns.14Early E

11、quipment Management Optimizes equipment selection through:n Equipment Life Cycle Cost Analysis:analysis of the sum of all costs(direct and indirect)associated with an item of equipment throughout its period of use.n MP Design:activity which is focused on minimizing future maintenance costs and produ

12、ction losses of equipment at the design stage.15Total Productive MaintenanceWithout TPMWith TPMMED&Industrial EngineeringMaintenanceMED&Industrial EngineeringOperationMaintenanceThe operator operates,maintenance maintains,etc.Shared responsibilitiesOperation16Equipment Maintenance ResponsibilitiesOp

13、erationMaintenanceMED&Industrial EngineeringAutonomous maintenanceBreakdown maintenancePlanned maintenancePredictive maintenanceMaintenance prevention17Total Productive MaintenanceTPMEquipment in better working conditionDecrease of breakdownsDecrease of in-process adjustmentsOptimization of operatio

14、n speedManufacturing defectsLead-timeQuality the first time18Performance Excellence:Expanding the Strategy through TPMIntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management19Total Productive MaintenanceTP

15、M,the total approachnThe operator is the first line caretakernMaintenance personnel are the specialized caretakers.20Division of Maintenance Duties betweenProduction and MaintenanceDepending on knowledge and skills required,responsibility for equipment maintenance tasks needs to be defined:Maintenan

16、ce TechnicianProduction Operator*Equipment overhaul*Basic lubrication*Special skill tasks*General cleaning*Complex adjustments*Multi-point inspection*High safety risk tasks*Basic adjustments21Maintenance Task Allocation betweenProduction and MaintenanceMaintenanceTechniciansProductionOperatorsAutono

17、mous maintenance implementationVolume of maintenance tasks22Performance Excellence:Expanding the Strategy through TPMIntroductionRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management23Autonomous means“independent”Au

18、tonomous maintenance refers to activities involving operators in the maintenance of their own equipment.Autonomous Maintenance24Autonomous MaintenanceHow to make the operator more independent:n Make the documentation available(manual,maintenance schedule,log book).n As a team,define manufacturing/ma

19、intenance/MED productive maintenance activities.n Show operator how to perform daily checks and take corrective actions.n Train in basic operation,maintenance and defect detection techniques.n Make daily activities visiblen Clearly identify items to supervise25Process Critical Machinery&EquipmentMap

20、 the process and identify critical equipmentTurningDrillingCuttingCleaningStripping&PaintingShipping26Adverse effects of inadequate cleaning27Adverse effects of inadequate cleaning:n Failure-equipment failure resulting from dirt and contamination affecting precisionn Product defects-contamination of

21、 products or defects arising from insufficient cleaningn Accelerated deterioration-dirt and scale buildup shortening useful equipment lifen Throughput loss-reduction in output due to loss of operation speed due to grime and contamination.28Equipment DeteriorationNormal deterioration:deterioration th

22、at occurs despite correct use and maintenanceAccelerated deterioration:quicker deterioration occurring due to misuse in operation and neglect of maintenance.29PerformanceTimeEquipment Breakdown100%Time and Deterioration of PerformanceNeed for detection of performance decline30Cleaning as Detection o

23、f DeteriorationnCleaning-reduces accelerated deteriorationnPhysical contact with equipment-exposes abnormal operating conditions(i.e.vibration,noisy bearings,leaks,overheating,frayed belts,inoperative indicators,etc.)nPreventive action taken-extends useful life and avoids breakdowns31A good clean-up

24、 allows for a good inspectionNoiseVibrationHeatOilDirtQuickly detectAnd documentCleaning as Detection of Deterioration32 Factors Contributing to Equipment Failure:Equipment failuresLoose partsVibrationContaminationImproper/InadequateLubrication33 Eliminate Factors Contributing to Failure:Secure and

25、tighten all fasteners,fittings,bolts and screws Replace any missing parts Replace any damaged,worn or wrong size parts Resolve all causes of leaks,spillage,spray and scatterImprove accessibility in order to accomplish Cleaning Lubricating Adjusting Checking34Total Productive MaintenanceSelf Maintena

26、nce-Operator_Equipment DescriptionI.D.#_Date:_Found by:_Description:Description:Total Productive MaintenanceSelf Maintenance-Maintenance_Equipment DescriptionI.D.#_Date:_Found by:_Autonomous Maintenance:Tagging Abnormalities35Tagging AbnormalitiesCleaning will uncover problems and undesirable condit

27、ions.Attach tag to make problem visibleResolves problems promptly and remove tags.Document plans to address those that cant be removed immediately.Autonomous Maintenance36Before Tags are Removed,Ask The 5“Whys”Problem:Oil leaks from the hydraulic press1.Why?Clogged filter2.Why?Oil was dirty3.Why?Met

28、al filings got into oil4.Why?Oil fill cap missing5.Why?Misplaced&lostFind the root causeSolution!Oil filler cap attached to filler neck by a chain(Poka-Yoke)37Equipment Performance LossesnDowntime losses-time lost to equipment breakdowns,machine adjustmentsnEfficiency losses-time lost to start up an

29、d operating cycle speeds less than idealnDefect losses-time lost to machine related quality defects and recycling.38Equipment Performance LossesLossGoalActionDowntimeLossesZeroEliminate breakdowns andintermittent stoppages.EfficiencyLossesMinimizeShrink set-up and adjustment times.Minimize differenc

30、es between ratedand actual equipment speeds.Defects&ReworkLossesZeroReduce to a minimum PPM range of30-100.39Assignable Loss versus Common LossDefect rateTimeAssignable loss-corrected by restoring to original conditionsCommon loss-reduced by achieving optimal conditions40Importance of LubricationnSo

31、me experts estimate 60%of machine breakdowns associated with moving parts are due to lack of or improper lubrication practices.Moving Part Machine Breakdowns60%40%Lubrication relatedOther causes41 Lubrication Management?The need to lubricate equipment correctly and consistentlynaccording to usagenwi

32、th correct lubricantsnin the correct amountnat specified fittingsnat specified time intervalsnensuring coverage of contact areas42Visual Management of LubricantsGreenBlueOrangeRed w/White stripeOilGreaseHydraulic fluidSilicone43Maintenance ChecklistsTPM VERIFICATION LISTAt The Beginning of Each Shif

33、tHydraulic Pressure Leaks(oil,fluids)Caps and hosesSwitchesLights and lampsBodyNoises/vibrationAt The End of Each ShiftCleanMake entry in maintenance book44Elapsed timeCompleted by:Point No.LocationStandardMethodProblem response DailyWeeklyMonthly Other2Fan ScreenNo lint or debrisVacuumInform superv

34、isor X1 min.B.Stevens4Fan ScreenNo lint or debrisVacuumInform supervisor X1 min.B.Stevens6Fan ScreenNo lint or debrisVacuumInform supervisor X1 min.B.Stevens8Fan ScreenNo lint or debrisVacuumInform supervisor X1 min.B.Stevens1Lube fittingLithium-2 ouncesGrease gunGrease if dry X.5 min.B.Stevens3Lube

35、 fittingLithium-2 ouncesGrease gunGrease if dry X.5 min.B.Stevens5Lube fittingLithium-2 ouncesGrease gunGrease if dry X.5 min.B.Stevens7Lube fittingLithium-2 ouncesGrease gunGrease if dry X.5 min.B.Stevens9Lube fittingLithium-2 ouncesGrease gunGrease if dry X.5 min.B.Stevens10Lube fittingLithium-2 o

36、uncesGrease gunGrease if dry X.5 min.B.Stevens7.0 minEquipment Name:RF1D1 DiecutterAutonomous Maintenance StandardLocation CleanLubricateTotalRevision Date:3/01/00Tag No.C-0012TPMStandard#10081Frequency Interval12345678910Example Cleaning and Lubrication for Autonomous Maintenance45Basic Training in

37、 EquipmentnConduct equipment training for leaders.nLeaders then train group members.nOperators implement training to correct abnormalities and improve equipment performance.nImplement visual controls.46Example Skills MatrixBasic Training in EquipmentOperation102030405060Equipment typeSMDChip-shooter

38、 Cut&ClinchPin&BushingWave solderPost-Wave Wash David B.Linda W.Matt S.Debbie M.Steve H.John S.Jessica L.Legend:Knows basics Can do with help Can do w/o help Can teach someone elsePrinted Circuit Assembly Equipment Specialists47One Point LessonPurpose:nTo provide specific knowledge about a single to

39、pic of importance.nFacilitate team training in an easy manner.nDiscussed on the shop floor.Types:nKnowledgenImprovementsnSolutions to problems48Object Name:Fasteners Subject:IdentificationNumber:Generic typesDate prepared:4/17/00By:John ClarkApproved:Tina JonesOne-Point Lesson SheetDepartmentDate tr

40、ainedNamePurpose:Identification of fastener hardware for repairs and ordering of replacements.Maint.PurchasingInventory StoresType:KnowledgeProblemImprovementxOne Point LessonProduction49TPM Deployment Effectiveness through Overlapping TeamsPlant ManagerStaff ManagerStaff ManagerStaff ManagerDept.Ma

41、nagerDept.ManagerDept.ManagerSupervisorSupervisorSupervisorSupervisorOperatorOperatorOperatorOperatorOperatorMaximizing Communication&CoordinationTeam leaders50Build a Time Based Maintenance SystemDetermine equipment for time based maintenanceDevelop maintenance criteria and intervalsTrain for maint

42、enance implementationExecute periodic maintenance Was maintenance effective?NoRevise maintenance instructions/parts provisioning51Establish an Equipment Failure DatabasenGather and manage equipment failure information.nAnalyze for trends and patterns of recurrence.nDevelop and issue periodic equipme

43、nt failure summary reports.nInclude failure summary reports as a meeting agenda item for regular review,discussion and improvement action planning.52Predictive Maintenance as a Diagnostic ToolAbnormalCharacteristicDiagnosticMethodPossible CausesVibration *Vibration meters *Material wear *Deteriorati

44、ng lubricantBlockages *Pressure gauges *Foreign matter *Faulty valvesLeaks *Pressure gauges *Thickness measurements *Corrosion *Worn gasketsContamination *Material or Fluid analysis *Foreign material *Improper procedure53Predictive Maintenance DeploymentDetermine equipment suitable for Predictive Ma

45、intenanceDevelop diagnostic methods and instructionsDiagnose equipment as definedExecute repair Repair/Overhaul Needed?YesRevise maintenance instructions/parts provisioningDocument repair informationEvaluate and revise diagnostic criteria54Maintenance Audits Audits are the most important factor in t

46、he successful implementation of an Autonomous Maintenance Program.They:n Verify success of implementation at each stepn Provide improvement feedbackn Instill a sense of achievement and reinforce continuing effort toward goals 55Maintenance Audits Implementation of autonomous maintenance group activi

47、tiesRequest for audit forwarded to TPM coordinatorAudit performedResults documentedPost audit meeting conductedAudit action items addressedPassedYesNo Congratulate Team Begin implementation of next TPM activityExample Audit Cycle 56Performance Excellence:Expanding the Strategy through TPMIntroductio

48、nRole in Lean ManufacturingRole of the Operator in TPMAutonomous Maintenance ImplementationEquipment Performance:Measurement and Management57Overall Equipment Effectiveness Overall Equipment Effectiveness =Availability x Efficiency rate x Quality ratenAn index of the overall operating performance of

49、 equipmentnPoints to the need to Eliminate stoppagesIncrease operating speed.Improve quality(less defects,rework,scrap)58Equipment effectiveness measurementDowntime lossesEfficiency lossesDefect lossesAvailability=(Shift time-non-operating time)-downtime Shift time-non-operating timeQuality rate=Pro

50、duction quantity-defectivesProduction quantity Efficiency rate=measured production rate standard production rateEquipment breakdownsSet-ups and adjustmentsEquipment actual speed versus rated speedQuality defectsOverall Equipment Effectiveness=Availability x Efficiency rate x Quality rate 59Tracking

51、Improvement Impacts On Overall Equipment EffectivenessBaseline12/991/002/003/004/005/006/007/00GoalOverall EquipmentEffectiveness%(A x E x Q)4453606688Availability%7276808395Efficiency rate%6773788195Quality rate%9195979898Breakdown reductionsSet-up reductionsRework reductionsImproved equipment spee

52、dsDefect reductionsImprovement Activities60The Mission Board:A Roadmap to ActionMission BoardTeam Name _Leader:_Members:_ _ _ _Mission:_ _ _Targets:_ _ _ Solder Overall Wave Effectiveness AvailabilityEfficiencyQualityActions:_ _ _Evaluation:_ _ _Results:_ _ _61Maintenance Information Management Syst

53、em Maintenance Information Management SystemOverall Equipment EffectivenessCost accountingLabor&material costsMaterial ControlUsage and inventoryHuman ResourcesStaffing&skills requirementsQuality Assurance Product quality ProductivityMaintenance information in relation to other business process syst

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