一份老外的tpm講義

1、 A STRATEGY FOR PERFORMANCE EXCELLENCE 1 Performance Excellence Series Training Module Elements Executive Overview Knowledge Breakthrough Tools Workbook Lecture notes Lecture notes Participant manual 2 Table of Contents Executive Overview Session 1.0 Session 2.0 Session 3.0 Session 4.0 Introduction.

2、3 Role in Lean Manufacturing.8 Role of the Operator in TPM.18 Autonomous Maintenance Implementation22 Equipment Performance: Measurement & Management.56 Session 5.0 3 Total Productive Maintenance Do these problems sound familiar? ?Equipment is always breaking down ?Operating machines at rated speeds

3、 creates defects Setups and adjustments take too long Minor machine stoppages are eroding productivity ? ? 4 Total Productive Maintenance A series of methods to ensure that process machines are always able to perform their functions so that production is never interrupted. 5 Total Productive Mainten

4、ance What it is: 1. Optimizes equipment efficiency 2. Implements a company wide Preventive Maintenance system 3. Involves production equipment designers, operators, and maintenance department personnel 4. Involvement from Management down to floor workers 5. Implemented through small, self directed t

5、eam activities 6 Total Productive Maintenance Typical success results after implementation of TPM: Breakdowns: Productivity: 1/30 to 1/100 of prior level 30 - 100 percent increase Machine defects: 1/30 to 1/40 of prior level source: K. Shirose, TPM For Workshop Leaders, p. 10 7 Performance Excellenc

6、e: Expanding the Strategy through TPM Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management 8 The Nine types of waste 9 Wastes ? ? ? ? ? ? ? ? ? Overproduction Delays (waiting time) Transportation P

7、rocess Inventories Motions Defective products Untapped resources Misused resources TPM targets reduction of these equipment oriented wastes 9 TPM: A Lean Manufacturing Method TPM and one-piece flow: Yesterday: Problem = machine breakdown = get around the problem Solution = Work in batches “ We use t

8、he time it works to mass produce ” Today: Objective = One piece flow Quality every time Means = TPM “We organize so it works continuously ” 10 Goals of TPM ? Achieve zero equipment breakdowns and zero defects through prevention. Establish prevention by ? Maintaining normal conditions ? Early detecti

9、on of abnormalities ? Quick response ? 11 Present Conditions ? ? ? Operators view machines as responsible for major production And limit their roles to equipment operation and inspecting for quality While maintenance workers view their function as responding to recurring breakdowns 12 Maintenance Ap

10、proaches Time Based or Planned Maintenance - Periodically scheduled maintenance actions. Predictive Maintenance - Maintenance action performed resulting from evaluation of equipment condition. Corrective Maintenance - Maintenance action performed to restore optimal equipment function. Preventive Mai

11、ntenance - A combination of Time based and Predictive Maintenance and actions taken to sustain optimal equipment performance and preclude breakdowns. 13 Early Equipment Management Optimizes equipment selection through: ?Equipment Life Cycle Cost Analysis : analysis of the sum of all costs (direct an

12、d indirect) associated with an item of equipment throughout its period of use. ? MP Design: activity which is focused on minimizing future maintenance costs and production losses of equipment at the design stage. 14 Total Productive Maintenance Without TPM With TPM MED & Industrial Engineering Opera

13、tion MED & Industrial Engineering Operation The operator operates, maintenance maintains, etc. Maintenance Maintenance Shared responsibilities 15 Equipment Maintenance Responsibilities Autonomous maintenance Operation MED & Industrial Engineering Maintenance prevention Maintenance Breakdown maintena

14、nce Planned maintenance Predictive maintenance 16 Total Productive Maintenance Decrease of breakdowns TPM Equipment in better working condition Lead-time Decrease of in- process adjustments Optimization of operation speed Quality the first time Manufacturing defects 17 Performance Excellence: Expand

15、ing the Strategy through TPM Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management 18 Total Productive Maintenance TPM, the total approach ? The operator is the first line caretaker ? Maintenance pe

16、rsonnel are the specialized caretakers. 19 Division of Maintenance Duties between Production and Maintenance Depending on knowledge and skills required, responsibility for equipment maintenance tasks needs to be defined: Maintenance Technician * Equipment overhaul Production Operator * Basic lubrica

17、tion * Special skill tasks * Complex adjustments * High safety risk tasks * General cleaning * Multi-point inspection * Basic adjustments 20 Maintenance Task Allocation between Production and Maintenance Volume of maintenance tasks Maintenance Technicians Production Operators Autonomous maintenance

18、implementation 21 Performance Excellence: Expanding the Strategy through TPM Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management 22 Autonomous Maintenance Autonomous means “independent” Autonomous

19、 maintenance refers to activities involving operators in the maintenance of their own equipment. 23 Autonomous Maintenance How to make the operator more independent: ? Make the documentation available (manual, maintenance schedule, log book). ? As a team, define manufacturing/maintenance/MED product

20、ive maintenance activities. ? Show operator how to perform daily checks and take corrective actions. ? Train in basic operation, maintenance and defect detection techniques. ? Make daily activities visible ? Clearly identify items to supervise 24 Process Critical Machinery & Equipment ?Map the proce

21、ss and identify critical equipment Turning Drilling Cutting Cleaning Stripping & Painting Shipping 25 Adverse effects of inadequate cleaning 26 Adverse effects of inadequate cleaning: ? Failure - equipment failure resulting from dirt and contamination affecting precision ? Product defects - contamin

22、ation of products or defects arising from insufficient cleaning ? Accelerated deterioration - dirt and scale buildup shortening useful equipment life ? Throughput loss - reduction in output due to loss of operation speed due to grime and contamination. 27 Equipment Deterioration Normal deterioration

23、: deterioration that occurs despite correct use and maintenance Accelerated deterioration: quicker deterioration occurring due to misuse in operation and neglect of maintenance. 28 Time and Deterioration of Performance 100% Performance Need for detection of performance decline Equipment Breakdown Ti

24、me 29 Cleaning as Detection of Deterioration Cleaning - reduces accelerated deterioration Physical contact with equipment - exposes ? ? abnormal operating conditions (i.e. vibration, noisy bearings, leaks, overheating, frayed belts, inoperative indicators, etc.) ? Preventive action taken - extends u

25、seful life and avoids breakdowns 30 Cleaning as Detection of Deterioration A good clean-up allows for a good inspection Noise Dirt Heat Quickly detect Oil And document Vibration 31 Factors Contributing to Equipment Failure: Equipment failures Contamination Vibration Loose parts Improper/ Inadequate

26、Lubrication 32 Eliminate Factors Contributing to Failure: ? Secure and 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 scatter Improve accessibility in order to accomplish

27、 ? Cleaning ? Lubricating ? Adjusting ? Checking 33 Autonomous Maintenance: Tagging Abnormalities Total Productive Maintenance Self Maintenance - Operator _ Equipment Description I.D.#_Date:_ Found by:_ Description: Total Productive Maintenance Self Maintenance - Maintenance _ Equipment Description

28、I.D.#_Date:_ Found by:_ Description: 34 Autonomous Maintenance Tagging Abnormalities Cleaning will uncover problems and undesirable conditions. ?Attach tag to make problem visible ?Resolves problems promptly and remove tags. ?Document plans to address those that cant be removed immediately. 35 Befor

29、e Tags are Removed, Ask The 5 “Whys” Problem: Oil leaks from the hydraulic press 1. Why? Clogged filter 2. Why? Oil was dirty 3. Why? Metal filings got into oil 4. Why? Oil fill cap missing 5. Why? Misplaced & lost Find the root cause Solution! Oil filler cap attached to filler neck by a chain (Poka

30、-Yoke) 36 Equipment Performance Losses Downtime losses - time lost to equipment breakdowns, machine adjustments ? ? Efficiency losses - time lost to start up and operating cycle speeds less than ideal Defect losses - time lost to machine related quality defects and recycling. ? 37 Equipment Performa

31、nce Losses Loss Downtime Losses Efficiency Losses Goal Zero Minimize Action Eliminate breakdowns and intermittent stoppages. Shrink set-up and adjustment times. Minimize differences between rated and actual equipment speeds. Defects & Rework Losses ZeroReduce to a minimum PPM range of 30-100. 38 Ass

32、ignable Loss versus Common Loss Defect rate Assignable loss - corrected by restoring to original conditions Common loss - reduced by achieving optimal conditions Time 39 Importance of Lubrication ?Some experts estimate 60% of machine breakdowns associated with moving parts are due to lack of or impr

33、oper lubrication practices. Moving Part Machine Breakdowns Lubrication related Other causes 40% 60% 40 Lubrication Management ? The need to lubricate equipment correctly and consistently ? according to usage ? ? ? ? ? with correct lubricants in the correct amount at specified fittings at specified t

34、ime intervals ensuring coverage of contact areas 41 Visual Management of Lubricants Green Blue Orange Red w/ White stripe Oil Grease Hydraulic fluid Silicone 42 Maintenance Checklists TPM VERIFICATION LIST At The Beginning of Each Shift ?Hydraulic Pressure ?Leaks (oil, fluids) ?Caps and hoses ?Switc

35、hes ?Lights and lamps ?Body ?Noises/vibration At The End of Each Shift ?Clean ?Make entry in maintenance book 43 Example Cleaning and Lubrication for Autonomous Maintenance Autonomous Maintenance Standard TPM Equipment Name: RF1D1 Diecutter Location Standard # 10081 Revision Date: 3/01/00 Tag No. C-

36、0012 3 2 1 4 5 6 7 8 9 10 Point No. 2 4 Clean 6 8 1 3 5 Lubricate 7 9 10 Total Location Fan Screen Fan Screen Fan Screen Fan Screen Lube fitting Lube fitting Lube fitting Lube fitting Lube fitting Lube fitting Standard No lint or debris No lint or debris No lint or debris No lint or debris Lithium -

37、 2 ounces Lithium - 2 ounces Lithium - 2 ounces Lithium - 2 ounces Lithium - 2 ounces Lithium - 2 ounces Method Vacuum Vacuum Vacuum Vacuum Grease gun Grease gun Grease gun Grease gun Grease gun Grease gun Frequency Interval Problem response DailyWeeklyMonthlyOther Inform supervisor X Inform supervi

38、sor X Inform supervisor X Inform supervisor X Grease if dry X Grease if dry X Grease if dry X Grease if dry X Grease if dry X Grease if dry X Elapsed Completed timeby: 1 min. 1 min. 1 min. 1 min. .5 min. .5 min. .5 min. .5 min. .5 min. .5 min. 7.0 min B. Stevens B. Stevens B. Stevens B. Stevens B. S

39、tevens B. Stevens B. Stevens B. Stevens B. Stevens B. Stevens 44 Basic Training in Equipment ? Conduct equipment training for leaders. Leaders then train group members. Operators implement training to correct abnormalities and improve equipment performance. Implement visual controls. ? ? ? 45 Basic

40、Training in Equipment Example Skills Matrix Printed Circuit Assembly Equipment Specialists Operation Equipment type 10 SMD 20 30 40 Pin & Bushing 50 Wave solder 60 Post-Wave Wash Chip-shooter Cut & Clinch David B. Linda W. Matt S. Debbie M. Steve H. John S. Jessica L. Legend: Knows basics Can do wit

41、h help Can do w/o help Can teach someone else 46 One Point Lesson Purpose: ? ? ? To provide specific knowledge about a single topic of importance. Facilitate team training in an easy manner. Discussed on the shop floor. Types: ? ? ? Knowledge Improvements Solutions to problems 47 One Point Lesson Ob

42、ject Name: Fasteners Type: Subject: Identification Number: Generic types One-Point Lesson Sheet Knowledge Problem Improvement Clark John Approved: Tina Jones Purpose: Identification of fastener hardware for repairs and ordering of replacements. By: x Date prepared: 4/17/00 Department Date trained Ma

43、int. Purchasing Inventory Stores Production Name 48 TPM Deployment Effectiveness through Overlapping Teams Team leaders Plant Manager Staff Manager Staff Manager Staff Manager Maximizing Communication & Dept. Manager Dept. Manager Dept. Manager Coordination Supervisor Supervisor Supervisor Superviso

44、r Operator Operator Operator Operator Operator 49 Build a Time Based Maintenance System Determine equipment for time based maintenance Develop maintenance criteria and intervals Train for maintenance implementation Execute periodic maintenance Was maintenance effective? No Revise maintenance instruc

45、tions / parts provisioning 50 Establish an Equipment Failure Database ?Gather and manage equipment failure information. ?Analyze for trends and patterns of recurrence. ?Develop and issue periodic equipment failure summary reports. ?Include failure summary reports as a meeting agenda item for regular

46、 review, discussion and improvement action planning. 51 Predictive Maintenance as a Diagnostic Tool Abnormal Characteristic Vibration Blockages Diagnostic Method * Vibration meters * Pressure gauges * Pressure gauges * Thickness measurements * Material or Fluid analysis Possible Causes * Material we

47、ar * Deteriorating lubricant * Foreign matter * Faulty valves * Corrosion * Worn gaskets * Foreign material * Improper procedure Leaks Contamination 52 Predictive Maintenance Deployment Determine equipment suitable for Predictive Maintenance Develop diagnostic methods and instructions Diagnose equip

48、ment as defined Evaluate and revise diagnostic criteria Repair/Overhaul Needed? Yes Execute repair Revise maintenance instructions / parts provisioning Document repair information 53 Maintenance Audits Audits are the most important factor in the successful implementation of an Autonomous Maintenance

49、 Program. They : ?Verify success of implementation at each step ?Provide improvement feedback ?Instill a sense of achievement and reinforce continuing effort toward goals 54 Maintenance Audits Implementation of autonomous maintenance group activities Request for audit forwarded to TPM coordinator ?A

50、udit performed ?Results documented ?Post audit meeting conducted Audit action items addressed ?Congratulate Team ?Begin implementation of next TPM activity Yes Passed No Example Audit Cycle 55 Performance Excellence: Expanding the Strategy through TPM Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management 56 Overall Equipment Effectiveness Overall Equipment Effectiveness = Availability x Efficiency rate x Quality rate ? An index of the overa