全員生產(chǎn)保養(yǎng)

1、Time Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 2 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB TPM概略概略 TPM Overview TPM

2、目的目的 The Aim of TPM TPM流程流程 TPM Process 自主保養(yǎng)自主保養(yǎng) Autonomous Maintenance 計(jì)劃保養(yǎng)計(jì)劃保養(yǎng) Planned Maintenance 預(yù)防工程預(yù)防工程 Preventive Engineering 教育與行動(dòng)教育與行動(dòng) Education & Practice 保證質(zhì)量保證質(zhì)量 Insured Quality TPM改善活動(dòng)改善活動(dòng) TPM Kaizen Activities TPM活動(dòng)進(jìn)階活動(dòng)進(jìn)階 Advanced TPM ActivitiesTime Based ManagementP SKB 2008 TBM C

3、onsulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 4 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB是這樣一個(gè)系統(tǒng)是這樣一個(gè)系統(tǒng)otal roductive aintenance is a system that 涉及工場(chǎng)涉

4、及工場(chǎng) / 維修人員維修人員Involves both shopfloor associates and maintenance associates 支持支持精益西格瑪流程精益西格瑪流程Supports the LeanSigma Process 保持設(shè)備最佳狀態(tài)保持設(shè)備最佳狀態(tài)Keeps equipment in optimal condition 8 - 5 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 忽視設(shè)備基本狀況忽視設(shè)備基本狀況Basic Equipment conditions neglected 操作維修技

5、能欠佳操作維修技能欠佳Insufficient operating and maintenance skills 設(shè)備設(shè)計(jì)固有不足設(shè)備設(shè)計(jì)固有不足Inherent weakness in equipment design 設(shè)備惡化無(wú)人監(jiān)督設(shè)備惡化無(wú)人監(jiān)督Overlooked deterioration 沒有遵守使用要求沒有遵守使用要求Usage conditions not observed 8 - 6 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBTPM世界性的公司世界性的公司W(wǎng)orld Wide Company工人自主保養(yǎng)

6、工人自主保養(yǎng)OperatorAutonomousMaintenance預(yù)防保養(yǎng)預(yù)防保養(yǎng)Preventive Maintenance經(jīng)理支持功能經(jīng)理支持功能ManagerSupportFunction工程設(shè)備工程設(shè)備設(shè)計(jì)改善設(shè)計(jì)改善Eng. Equip.DesignImprovement品質(zhì)改善品質(zhì)改善QualityImprovement全員生產(chǎn)保養(yǎng)全員生產(chǎn)保養(yǎng)T P M高級(jí)管理層高級(jí)管理層領(lǐng)導(dǎo)領(lǐng)導(dǎo) S M L生產(chǎn)準(zhǔn)備生產(chǎn)準(zhǔn)備2P西格瑪改善西格瑪改善Sigma Kaizen8 - 7 2008 TBM Consulting Group, Inc. All Rights Reserved.P SK

7、B 零故障零故障 Zero Breakdowns 零缺陷零缺陷 Zero Defects 零事故零事故 Zero Accidents 全員參與全員參與 Total employee involvement 提高機(jī)器效率提高機(jī)器效率, 滿足節(jié)拍滿足節(jié)拍速度速度Achieve Takt Rate at the highest machine effectiveness 8 - 8 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB機(jī)器可靠機(jī)器可靠Machine Reliability機(jī)器高效機(jī)器高效Machine Effectiven

8、ess聯(lián)動(dòng)操作聯(lián)動(dòng)操作Linked Operations人力利用人力利用Labor Utilization制程能力制程能力Process Capability最佳機(jī)況最佳機(jī)況Optimal machine conditions制程重復(fù)制程重復(fù)Process Repeatability防錯(cuò)裝置防錯(cuò)裝置Mistake Proofing8 - 9 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB每班每班8小時(shí)小時(shí) 8 hr shift有效時(shí)間有效時(shí)間 = 7小時(shí)小時(shí)40分分 Effectiveness = 7 hrs 40min工人開

9、會(huì)工人開會(huì): 10分鐘分鐘Operator Meeting10 min10 min設(shè)備清潔與潤(rùn)滑設(shè)備清潔與潤(rùn)滑: 10分鐘分鐘Equipment cleaning & Lubrication 本班開始本班開始 Shift Start品質(zhì)問(wèn)題品質(zhì)問(wèn)題 Quality暫停暫停 Minor Stoppages故障停機(jī)故障停機(jī) Breakdown調(diào)整調(diào)整 Adjustment本班結(jié)束本班結(jié)束 Shift End每班每班8小時(shí)小時(shí) 8 hr shift有效時(shí)間有效時(shí)間 = 6小時(shí)小時(shí) Effectiveness = 6 hrs8 - 10 2008 TBM Consulting Group, I

10、nc. All Rights Reserved.P SKB整體設(shè)備效率整體設(shè)備效率 Overall Equipment Effectiveness (OEE) 可用效率可用效率 Availability 性能效率性能效率 Performance 品質(zhì)效率品質(zhì)效率 Quality保養(yǎng)效率保養(yǎng)效率 Maintenance Effectiveness 平均故障時(shí)間間隔平均故障時(shí)間間隔 MTTF (Mean time to failure) 平均無(wú)故障時(shí)間平均無(wú)故障時(shí)間 MTBF (Mean time between failure) 平均維修時(shí)間平均維修時(shí)間 MTTR (Mean time to r

11、epair)Time Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc. 改善設(shè)備運(yùn)行狀況改善設(shè)備運(yùn)行狀況To improve the equipment operating condition 維持設(shè)備最佳性能與可靠性維持設(shè)備最佳性能

12、與可靠性To sustain equipment at an optimal level of performance & reliability 延長(zhǎng)設(shè)備使用壽命延長(zhǎng)設(shè)備使用壽命To lengthen the life expectancy of equipment Time Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are

13、 registered trademarks of TBM Consulting Group Inc.8 - 13 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB自主保養(yǎng)自主保養(yǎng) Autonomous Maintenance計(jì)劃保養(yǎng)計(jì)劃保養(yǎng)PlanningMaintenance預(yù)防工程預(yù)防工程PreventiveEngineering品質(zhì)品質(zhì)Quality 教育與行動(dòng)教育與行動(dòng)Education& Practice8 - 14 2008 TBM Consulting Group, Inc. All Rights Res

14、erved.P SKB1.測(cè)量工作單元上所有自動(dòng)設(shè)備之測(cè)量工作單元上所有自動(dòng)設(shè)備之OEEMeasure OEE for all automatic equipment in cells. 2.測(cè)量各工作單元的節(jié)拍時(shí)間測(cè)量各工作單元的節(jié)拍時(shí)間Measure Takt rate performance for each area. 3.將單元節(jié)拍時(shí)間與設(shè)備將單元節(jié)拍時(shí)間與設(shè)備OEE進(jìn)行比較進(jìn)行比較Correlate cell takt rate performance to equipment OEE. 4.選擇特定機(jī)器作為改善重點(diǎn)選擇特定機(jī)器作為改善重點(diǎn)Select specific machi

15、ne for kaizen focus. 5.根據(jù)根據(jù)OEE六大損失制定改善目標(biāo)六大損失制定改善目標(biāo)Establish improvement goal related to the six major losses of OEE.6.選定設(shè)備改善專職隊(duì)員選定設(shè)備改善專職隊(duì)員Select permanent equipment improvement team members.7.發(fā)動(dòng)工人進(jìn)行自主保養(yǎng)及計(jì)劃保養(yǎng)活動(dòng)發(fā)動(dòng)工人進(jìn)行自主保養(yǎng)及計(jì)劃保養(yǎng)活動(dòng)Initiate operator autonomous maintenance and planned maintenance programs.

16、 8.繼續(xù)更新檢查單繼續(xù)更新檢查單, 培訓(xùn)工人培訓(xùn)工人, 保證機(jī)器最佳狀況保證機(jī)器最佳狀況Continue to update check lists, train operators, and pursue optimal machine conditions. 9.為選定設(shè)備設(shè)立為選定設(shè)備設(shè)立TPM活動(dòng)之目視表現(xiàn)板活動(dòng)之目視表現(xiàn)板Establish visual performance boards for TPM activities on selected equipment. 10.每月將改善目標(biāo)與實(shí)際結(jié)果進(jìn)行比較。評(píng)價(jià)是否需要進(jìn)行更多改善活動(dòng)每月將改善目標(biāo)與實(shí)際結(jié)果進(jìn)行比較。評(píng)價(jià)是

17、否需要進(jìn)行更多改善活動(dòng), 制定更制定更高的目標(biāo)高的目標(biāo), 或需要更換專職隊(duì)員或需要更換專職隊(duì)員Check results to improvement goals monthly. Evaluate need for additional kaizen activity, setting more aggressive goals, or modifying permanent team members. Time Based ManagementP SKB 2008 TBM Consulting Group, Inc. All Rights Reserved.LeanSigma, The P

18、erfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 16 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB工人要學(xué)習(xí)工人要學(xué)習(xí) A system where equipment operators learn to : 進(jìn)行每日檢查進(jìn)行每日檢查 Perform daily checks 按需潤(rùn)滑設(shè)備按需潤(rùn)滑設(shè)備 Lubricate equip

19、ment as needed 更換簡(jiǎn)單零件更換簡(jiǎn)單零件 Replace simple components 進(jìn)行機(jī)器小修進(jìn)行機(jī)器小修 Perform minor repairs on machines 幫助解決問(wèn)題幫助解決問(wèn)題 Assist in problem solving8 - 17 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB1.進(jìn)行基本清潔活動(dòng)進(jìn)行基本清潔活動(dòng)Perform basic cleaning 2.根除骯臟污染源頭根除骯臟污染源頭Eliminate sources of dirt and contamin

20、ation 3.建立清潔潤(rùn)滑標(biāo)準(zhǔn)建立清潔潤(rùn)滑標(biāo)準(zhǔn)Establish cleaning and lubrication standards 4.教會(huì)設(shè)備基本檢查教會(huì)設(shè)備基本檢查, 進(jìn)行自主設(shè)備檢查進(jìn)行自主設(shè)備檢查Teach general inspection of equipment and Perform autonomous equipment inspection 5.培養(yǎng)整齊有序習(xí)慣培養(yǎng)整齊有序習(xí)慣Instill orderliness and organization 8 - 18 2008 TBM Consulting Group, Inc. All Rights Reserved

21、.P SKB 預(yù)防污染預(yù)防污染 Prevent deterioration : 維持基本條件維持基本條件Maintaining basic conditions 正確操作設(shè)備正確操作設(shè)備Operating equipment correctly 判斷污染判斷污染Measure deterioration : 進(jìn)行檢查進(jìn)行檢查Inspecting 制定標(biāo)準(zhǔn)制定標(biāo)準(zhǔn), 堅(jiān)持執(zhí)行堅(jiān)持執(zhí)行Developing and adhering to standards 糾正污染糾正污染Correct deterioration : 報(bào)告問(wèn)題報(bào)告問(wèn)題Reporting problems 協(xié)助維修協(xié)助維修Assi

22、sting in repairs 進(jìn)行微調(diào)進(jìn)行微調(diào) (按本地合約按本地合約)Making minor adjustments (per local contract) 加入團(tuán)隊(duì)加入團(tuán)隊(duì)Participate in teams : 工作中心團(tuán)隊(duì)工作中心團(tuán)隊(duì)Work center teams 解決問(wèn)題團(tuán)隊(duì)解決問(wèn)題團(tuán)隊(duì)Problem-solving teams 8 - 19 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 設(shè)備保養(yǎng)設(shè)備保養(yǎng)Maintain Equipment 檢驗(yàn)檢驗(yàn) (拆卸拆卸)Inspect (disassemb

23、ly) 計(jì)劃保養(yǎng)計(jì)劃保養(yǎng)Planned overhauls 預(yù)防保養(yǎng)預(yù)防保養(yǎng)Preventive maintenance 教導(dǎo)工人學(xué)會(huì)特定保養(yǎng)工作教導(dǎo)工人學(xué)會(huì)特定保養(yǎng)工作Teach selected maintenance tasks to operators 設(shè)備改善設(shè)備改善Improve Equipment 支持可靠性及可維修性改善支持可靠性及可維修性改善Support R&M improvement 實(shí)施預(yù)測(cè)技術(shù)實(shí)施預(yù)測(cè)技術(shù)Implement predictive technologies 糾正設(shè)計(jì)不足糾正設(shè)計(jì)不足Correct design weaknesses 搞好供方合作搞

24、好供方合作Partner with vendors 8 - 20 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 初步清潔初步清潔 Initial Cleaning 螺母、螺栓等有無(wú)松動(dòng)、搖擺、遺失螺母、螺栓等有無(wú)松動(dòng)、搖擺、遺失?Any nuts, bolts, etc. loose, wobbly or missing? 活動(dòng)零件、夾具安裝有無(wú)竄動(dòng)活動(dòng)零件、夾具安裝有無(wú)竄動(dòng)?Any play in moving parts or fixture mounting section? 機(jī)器內(nèi)部有無(wú)多余零件機(jī)器內(nèi)部有無(wú)多余零件?

25、Any unnecessary items located on the body of the machine? 潤(rùn)滑系統(tǒng)潤(rùn)滑系統(tǒng) Lubrication 潤(rùn)滑油是否到達(dá)滑動(dòng)部件潤(rùn)滑油是否到達(dá)滑動(dòng)部件? Does oil reach sliding parts? 潤(rùn)脂嘴、機(jī)油蓋等是否損壞、遺失潤(rùn)脂嘴、機(jī)油蓋等是否損壞、遺失?Any damaged or missing grease nipples, oil caps, etc.? 供油裝置、管路、接頭有無(wú)漏油供油裝置、管路、接頭有無(wú)漏油?Any oil or grease leaks from supply devices, pipes,

26、fittings? 加油工人有無(wú)內(nèi)外清潔加油工人有無(wú)內(nèi)外清潔? Are oilers clean inside or out? 油標(biāo)是否容易看見油標(biāo)是否容易看見? Is the oil level easily visible? 8 - 21 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 液壓系統(tǒng)液壓系統(tǒng) Hydraulics 油箱裝夠油了嗎油箱裝夠油了嗎? Is the oil tank filled to the specified level? 油泵發(fā)出異常噪音嗎油泵發(fā)出異常噪音嗎? Is the pump emitt

27、ing any abnormal noises? 卸荷閥、減壓閥、節(jié)流閥防松螺母上緊了嗎卸荷閥、減壓閥、節(jié)流閥防松螺母上緊了嗎?Are locknuts tight on relief, reducing and throttle valves? 卸荷閥、控制裝置運(yùn)作正常嗎卸荷閥、控制裝置運(yùn)作正常嗎?Are relief valves and controls operating correctly? 高壓管路連接變形或磨損了嗎高壓管路連接變形或磨損了嗎?Any strain or wear in high pressure hose connections? 電器系統(tǒng)電器系統(tǒng) Electri

28、cal 行程開關(guān)杠桿能夠完全接觸嗎行程開關(guān)杠桿能夠完全接觸嗎? Do limit switch bars strike fully? 信號(hào)燈、指示燈遺失或燒壞了嗎信號(hào)燈、指示燈遺失或燒壞了嗎?Any missing or burned out pilot or indicator lights? 配電盤、電器箱有無(wú)線路圖配電盤、電器箱有無(wú)線路圖?Are there wiring diagrams in the control panels or electrical boxes? 有無(wú)多余的、損壞的、壓壞的電線或軟管有無(wú)多余的、損壞的、壓壞的電線或軟管?Any unnecessary, dam

29、aged or dented wires or flexible tubing? 8 - 22 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 傳動(dòng)系統(tǒng)傳動(dòng)系統(tǒng) Power Transfer Devices V型皮帶碰到帶輪槽底了嗎型皮帶碰到帶輪槽底了嗎?Do V-belts hit the bottom of pulley grooves? 皮帶有無(wú)損壞、爆裂、破裂皮帶有無(wú)損壞、爆裂、破裂?Any damage, cracking or splitting of the belts? 滾柱鏈條的銷軸與軸承之間有無(wú)足夠潤(rùn)滑油滾

30、柱鏈條的銷軸與軸承之間有無(wú)足夠潤(rùn)滑油?Is there sufficient lubrication between pins and bushings of roller chains? 轉(zhuǎn)軸有無(wú)過(guò)熱、振動(dòng)、噪音轉(zhuǎn)軸有無(wú)過(guò)熱、振動(dòng)、噪音?Any shaft overheating, vibration or noise? 聯(lián)接系統(tǒng)有無(wú)鎖鍵、夾緊螺栓松動(dòng)造成的竄動(dòng)聯(lián)接系統(tǒng)有無(wú)鎖鍵、夾緊螺栓松動(dòng)造成的竄動(dòng)?Any play due to loose keys or clamping bolts on couplings? 齒輪機(jī)構(gòu)有無(wú)過(guò)量的躁音、發(fā)熱、振動(dòng)齒輪機(jī)構(gòu)有無(wú)過(guò)量的躁音、發(fā)熱、振動(dòng)?An

31、y excess noise, heat or vibration in gear mechanisms? 8 - 23 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 螺母螺栓螺母螺栓 Nuts and Bolts 登記記號(hào)允許松緊度檢查嗎登記記號(hào)允許松緊度檢查嗎?Do registration marks permit tightness checks? 螺母螺栓型號(hào)及尺寸正確嗎螺母螺栓型號(hào)及尺寸正確嗎?Are nuts and bolts of the suitable types or sizes used? 墊片尺寸

32、正確墊片尺寸正確, 且類型相配嗎且類型相配嗎?Are washers of proper size, and are they consistently used? 螺栓有從螺母凸出螺栓有從螺母凸出23圈螺紋嗎圈螺紋嗎?Do bolts protrude 2 3 threads from the nuts? 氣動(dòng)系統(tǒng)氣動(dòng)系統(tǒng) Pneumatics 截止閥及球閥漏氣嗎截止閥及球閥漏氣嗎? Any stop valve, ball valve leaks? 有壞了或多余的手把嗎有壞了或多余的手把嗎? Any broken or unnecessary handles? 已關(guān)閉的閥仍有氣流嗎已關(guān)閉的

33、閥仍有氣流嗎? Does any air flow through closed valves? 有任何不必要的裝置或喉管嗎有任何不必要的裝置或喉管嗎?Are any unnecessary devices, hoses or pipes present? 所有喉管都整齊及易于識(shí)別嗎所有喉管都整齊及易于識(shí)別嗎?Are pipes and hoses orderly and readily identifiable? 壓力表指示的都是正確設(shè)定的壓力嗎壓力表指示的都是正確設(shè)定的壓力嗎?Do pressure gauges clearly indicate the correct set press

34、ure? 8 - 24 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 做好清潔檢查做好清潔檢查 Clean to inspect 暴露隱藏不足暴露隱藏不足 Expose hidden defects 找出臟污源頭找出臟污源頭 Determine source of contamination 識(shí)別難于清潔之處識(shí)別難于清潔之處 Identify hard to reach areas 準(zhǔn)備藍(lán)色標(biāo)簽工作準(zhǔn)備藍(lán)色標(biāo)簽工作 Prepare for blue tag exercise8 - 25 2008 TBM Consulting

35、 Group, Inc. All Rights Reserved.P SKB臟污原因臟污原因 Causes of Contamination: 發(fā)生液體泄漏發(fā)生液體泄漏 Fluid leaks 碎片容器很差碎片容器很差 Poor chip containment 工作不佳工作不佳 Poor 5S practices 工作區(qū)有濺灑工作區(qū)有濺灑 Work area spills 過(guò)濾性能不好過(guò)濾性能不好 Poor filtration 沒有清潔標(biāo)準(zhǔn)沒有清潔標(biāo)準(zhǔn) No cleaning standards 無(wú)工作自豪感無(wú)工作自豪感 Poor work pride 環(huán)境問(wèn)題惡劣環(huán)境問(wèn)題惡劣 Envir

36、onment 8 - 26 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 從工人開始進(jìn)行基本的清潔、檢查及潤(rùn)滑活動(dòng)從工人開始進(jìn)行基本的清潔、檢查及潤(rùn)滑活動(dòng)Begin basic operator cleaning, inspecting and lubricating activities 制定臨時(shí)標(biāo)準(zhǔn)制定臨時(shí)標(biāo)準(zhǔn) Establish provisional standards 進(jìn)行重點(diǎn)訓(xùn)示進(jìn)行重點(diǎn)訓(xùn)示 Create one point lesson 確定活動(dòng)頻次確定活動(dòng)頻次 Establish frequency of a

37、ctivities 月檢、周檢、日檢清單月檢、周檢、日檢清單Monthly, weekly and daily check list 制做檢查表制做檢查表 Develop check list 8 - 27 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB1.0 目的目的/范圍范圍: 根據(jù)根據(jù)3600路線檢查單脂具體檢查步驟制定詳細(xì)的工作指示路線檢查單脂具體檢查步驟制定詳細(xì)的工作指示2.0 責(zé)任責(zé)任: 工人工人3.0 安全安全: 標(biāo)準(zhǔn)的工人保護(hù)設(shè)備標(biāo)準(zhǔn)的工人保護(hù)設(shè)備: 防護(hù)眼鏡防護(hù)眼鏡, 聽覺保護(hù)用具聽覺保護(hù)用具, 手套手套,

38、鋼頭鞋鋼頭鞋4.0 工作指示工作指示第第1步步: 本工作指示用于與本工作指示用于與3600路線檢路線檢查單有關(guān)的工作查單有關(guān)的工作第第2步步: 本工作指示用于本工作指示用于3600噸沖壓機(jī)噸沖壓機(jī)周圍的檢查工作周圍的檢查工作35第第3步步: 檢查模具加熱爐溫度及設(shè)定值。檢查模具加熱爐溫度及設(shè)定值。絕對(duì)最低設(shè)定值應(yīng)為絕對(duì)最低設(shè)定值應(yīng)為800度度8 - 28 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 制定詳細(xì)的培訓(xùn)計(jì)劃制定詳細(xì)的培訓(xùn)計(jì)劃Develop in depth training program 對(duì)工人就以下內(nèi)容進(jìn)行培

39、訓(xùn)：對(duì)工人就以下內(nèi)容進(jìn)行培訓(xùn)：Train operators in: 潤(rùn)滑作用潤(rùn)滑作用/粘性分析粘性分析 Lubrication/ Viscosity Analysis 氣動(dòng)系統(tǒng)氣動(dòng)系統(tǒng) Pneumatics 液壓系統(tǒng)液壓系統(tǒng) Hydraulic 電氣系統(tǒng)電氣系統(tǒng) Electrical systems 驅(qū)動(dòng)系統(tǒng)驅(qū)動(dòng)系統(tǒng) Drive systems 修改目前的重點(diǎn)訓(xùn)示修改目前的重點(diǎn)訓(xùn)示, 加入檢驗(yàn)檢查工作加入檢驗(yàn)檢查工作Revise existing one-point lessons to include inspection checks 8 - 29 2008 TBM Consulting

40、 Group, Inc. All Rights Reserved.P SKB 工場(chǎng)管理與控制工場(chǎng)管理與控制 Workplace management & control 擴(kuò)展團(tuán)隊(duì)活動(dòng)擴(kuò)展團(tuán)隊(duì)活動(dòng), 做好設(shè)備以外的整潔工作做好設(shè)備以外的整潔工作Expand team activities beyond equipment to other aspects of the process 搞好工場(chǎng)整潔搞好工場(chǎng)整潔, 實(shí)行目視控制，發(fā)現(xiàn)改善機(jī)會(huì)實(shí)行目視控制，發(fā)現(xiàn)改善機(jī)會(huì) (第第4、5個(gè)個(gè)S)Expose opportunities for improved organization, orde

41、rliness and visual control (4th & 5th S) 進(jìn)行進(jìn)行5S評(píng)審評(píng)審 Perform 5S audits 8 - 30 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB8 - 31 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 寫出已做的活動(dòng)寫出已做的活動(dòng), 展示取得的進(jìn)步展示取得的進(jìn)步Describes activities undertaken and shows progress 對(duì)比制定的標(biāo)準(zhǔn)對(duì)比制定的標(biāo)準(zhǔn),

42、量化取得的改善量化取得的改善 故障停機(jī)、維修呼故障停機(jī)、維修呼叫、停線時(shí)間等叫、停線時(shí)間等Quantifies the improvements made against agreed metrics. e.g. (Breakdowns, defects, maintenance call-outs, line down-time, etc.) 細(xì)化實(shí)際的改善細(xì)化實(shí)際的改善 Details the actual improvements made 記錄待研究項(xiàng)目記錄待研究項(xiàng)目 Records issues to be reviewed: 沒有答復(fù)的問(wèn)題沒有答復(fù)的問(wèn)題 Unanswered qu

43、estions 需要支援的問(wèn)題需要支援的問(wèn)題 Complex issues support required 8 - 32 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB問(wèn)題公報(bào)問(wèn)題公報(bào)ProblemNewspaper問(wèn)題公報(bào)問(wèn)題公報(bào)ProblemNewspaper生產(chǎn)保養(yǎng)完成率生產(chǎn)保養(yǎng)完成率PM Completion Ratio8 - 33 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBTime Based ManagementP SKB 2008 TBM

44、Consulting Group, Inc. All Rights Reserved.LeanSigma, The Perfect Engine, LeanStrategy, and the TBM Consulting Group logo are registered trademarks of TBM Consulting Group Inc.8 - 35 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB進(jìn)行進(jìn)行TPM基礎(chǔ)基礎(chǔ)知識(shí)培訓(xùn)，知識(shí)培訓(xùn)，評(píng)審準(zhǔn)備工評(píng)審準(zhǔn)備工作作Train in TPM fundamentals &

45、amp; Review Pre-work 實(shí)施藍(lán)色標(biāo)實(shí)施藍(lán)色標(biāo)簽方法簽方法Conduct Blue Tag Exercise 異常情況排異常情況排序序Rank abnormalities 異常情況維異常情況維修修Repair abnormalities設(shè)備設(shè)備OEM手手冊(cè)評(píng)審冊(cè)評(píng)審Review equipment OEM manuals 確定工人自確定工人自主保養(yǎng)路線主保養(yǎng)路線, 制定檢查表制定檢查表Create Op. AM route & Check sheet 定義定義 / 實(shí)施標(biāo)實(shí)施標(biāo)準(zhǔn)化工作準(zhǔn)化工作Define & Implement Std Work 實(shí)現(xiàn)保養(yǎng)反饋實(shí)

46、現(xiàn)保養(yǎng)反饋循環(huán)循環(huán)Implement feedback loop to maintenance 進(jìn)行進(jìn)行OEE表現(xiàn)表現(xiàn)公告公告Implement OEE performance board 向管理層展向管理層展示結(jié)果示結(jié)果Presentation to Mgrs. 8 - 36 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 收集改善活動(dòng)一個(gè)月前的停機(jī)數(shù)據(jù)收集改善活動(dòng)一個(gè)月前的停機(jī)數(shù)據(jù)Collect downtime data for one month prior to event 進(jìn)行設(shè)備基本清潔活動(dòng)進(jìn)行設(shè)備基本清潔活動(dòng)C

47、onduct initial cleaning of equipment 收集設(shè)備規(guī)格、收集設(shè)備規(guī)格、OEM手冊(cè)、機(jī)器手冊(cè)、機(jī)器BOM及圖紙及圖紙Gather machine specifications, OEM manuals, machine BOM, blueprints 8 - 37 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB 進(jìn)行兩小時(shí)的觀察進(jìn)行兩小時(shí)的觀察 Conduct two-hour observation 清潔臟污源頭清潔臟污源頭, 貼上藍(lán)色標(biāo)簽貼上藍(lán)色標(biāo)簽Clean and Blue Tag sou

48、rces of dirt and contamination 集思廣益集思廣益 按實(shí)施難易程度排序按實(shí)施難易程度排序Brainstorm ideas Prioritize according to implementation ease 實(shí)施解決方案實(shí)施解決方案, 消除臟污源頭消除臟污源頭Implement solutions to eliminate sources of contamination 設(shè)計(jì)工人自主保養(yǎng)路線、檢查表及重點(diǎn)訓(xùn)示設(shè)計(jì)工人自主保養(yǎng)路線、檢查表及重點(diǎn)訓(xùn)示, 實(shí)現(xiàn)保養(yǎng)標(biāo)準(zhǔn)實(shí)現(xiàn)保養(yǎng)標(biāo)準(zhǔn)化化Standardize and develop Operator Autonomous

49、 Maintenance Routes, Check Sheets and One-point lesson 實(shí)行實(shí)行OEE表現(xiàn)公告制度表現(xiàn)公告制度 Implement OEE performance board 實(shí)施設(shè)備保養(yǎng)反饋循環(huán)實(shí)施設(shè)備保養(yǎng)反饋循環(huán)Implement equipment maintenance feedback loop 8 - 38 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB改善前改善前 Before改善后改善后 After8 - 39 2008 TBM Consulting Group, Inc.

50、 All Rights Reserved.P SKB 識(shí)別臟污及異常源頭識(shí)別臟污及異常源頭 Identify sources of contamination and malfunctions 每個(gè)源頭貼上藍(lán)色標(biāo)簽每個(gè)源頭貼上藍(lán)色標(biāo)簽 Write a blue tag for each identified item 在機(jī)器上靠近源頭處掛上藍(lán)色標(biāo)簽在機(jī)器上靠近源頭處掛上藍(lán)色標(biāo)簽Attach blue tag to machine at location of specific item 在總表上記錄藍(lán)色標(biāo)簽資料在總表上記錄藍(lán)色標(biāo)簽資料Document Tag Information on Su

51、mmary Chart 與保養(yǎng)人員評(píng)審藍(lán)色標(biāo)簽與保養(yǎng)人員評(píng)審藍(lán)色標(biāo)簽, 按影響程度及修理難易程度排序按影響程度及修理難易程度排序Review tags with maintenance personnel as a team & rank according to impact & difficulty of repair 改善活動(dòng)期間沒有解決的異常問(wèn)題改善活動(dòng)期間沒有解決的異常問(wèn)題, 保養(yǎng)人員要做好行動(dòng)計(jì)劃保養(yǎng)人員要做好行動(dòng)計(jì)劃, 列明負(fù)列明負(fù)責(zé)人及時(shí)間要求責(zé)人及時(shí)間要求Maintenance completes Who and When information for ab

52、normalities not repaired during kaizen event and creates Action Plan 改善小組更新總表狀態(tài)改善小組更新總表狀態(tài) Team updates status of summary chart 在每月改善評(píng)審會(huì)議上在每月改善評(píng)審會(huì)議上, 專職隊(duì)員評(píng)審總表狀態(tài)專職隊(duì)員評(píng)審總表狀態(tài)Permanent team reviews status of summary chart at monthly kaizen review meeting 8 - 40 2008 TBM Consulting Group, Inc. All Rights R

53、eserved.P SKBBlue Tag - (part 1)Number:36702DateShiftBy :Problem ElectricalOperationMechanicalInstrument / ControlLubricationUtility / FacilityOther _Brief Description of Problem:Blue Tag - (part 2)Number:36702DateShiftBy :Location / System / Equipment / Part I.D.Problem ElectricalOperationMechanica

54、lInstrument / ControlLubricationUtility / FacilityOther _Description of Problem (continue on back):Possible Impact of Problem Availability (Uptime)WastePerformance / SpeedCostQuality of ProductSafetyEnviromentOther _Corrective Action Plan:W/O #By:Date:By:Date:By:Date:Root Cause / Action (continue on

55、 Back)Date Completed:_OK _藍(lán)色標(biāo)簽藍(lán)色標(biāo)簽藍(lán)色標(biāo)簽藍(lán)色標(biāo)簽第第1部分部分第第2部分部分編號(hào)編號(hào)編號(hào)編號(hào)日期日期日期日期檢查人檢查人檢查人檢查人班次班次班次班次問(wèn)題問(wèn)題問(wèn)題問(wèn)題電氣電氣機(jī)械機(jī)械潤(rùn)滑潤(rùn)滑操作操作儀器儀器 / 控制機(jī)構(gòu)控制機(jī)構(gòu)設(shè)備設(shè)備其它其它問(wèn)題簡(jiǎn)述問(wèn)題簡(jiǎn)述電氣電氣機(jī)械機(jī)械潤(rùn)滑潤(rùn)滑操作操作設(shè)備設(shè)備儀器儀器 / 控制機(jī)構(gòu)控制機(jī)構(gòu)其它其它問(wèn)題簡(jiǎn)述問(wèn)題簡(jiǎn)述, 繼續(xù)見背面繼續(xù)見背面問(wèn)題可能影響問(wèn)題可能影響可使用時(shí)間可使用時(shí)間性能性能/速度速度成品質(zhì)量成品質(zhì)量環(huán)境環(huán)境浪費(fèi)浪費(fèi)成本成本安全安全其它其它改正行動(dòng)計(jì)劃改正行動(dòng)計(jì)劃執(zhí)行人執(zhí)行人執(zhí)行人執(zhí)行人執(zhí)行人執(zhí)行人日期日期日

56、期日期日期日期工作單號(hào)工作單號(hào)根本原因根本原因 / 行動(dòng)行動(dòng), 更多見背面更多見背面完成日期完成日期位置位置 / 系統(tǒng)系統(tǒng) / 設(shè)備設(shè)備 / 零件代號(hào)零件代號(hào)8 - 41 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKB8 - 42 2008 TBM Consulting Group, Inc. All Rights Reserved.P SKBNo.異常異常 Malfunction行動(dòng)行動(dòng) Action負(fù)責(zé)人負(fù)責(zé)人Who 時(shí)間時(shí)間When OK1漏油漏油Oil leak重新設(shè)計(jì)油槽重新設(shè)計(jì)油槽, 引導(dǎo)及引導(dǎo)及接住導(dǎo)軌油接住導(dǎo)軌

57、油Need chute designed to guide and catch way lube oil 保養(yǎng)人員保養(yǎng)人員 Maint. 4/18/912油泵油泵濾網(wǎng)濾網(wǎng)上金屬過(guò)上金屬過(guò)濾器蓋彎曲濾器蓋彎曲Metal filter cover over the pump screen bent 弄直或更換弄直或更換Straighten or replace 改善隊(duì)員改善隊(duì)員Team 4/10/91已完成已完成Complete3蓋外殼時(shí)遺失兩個(gè)蓋外殼時(shí)遺失兩個(gè)螺絲螺絲 Two screws missing on way cover housing更換更換Replace 改善隊(duì)員改善隊(duì)員 Team

58、 4/18/91已完成已完成Complete4滑動(dòng)門上軌道滾柱滑動(dòng)門上軌道滾柱軸承遺失軸承遺失Roller bearing missing on the top track of the sliding door更換更換Replace 保養(yǎng)人員保養(yǎng)人員 Maint. 4/21/915Nachi液壓泵底下漏液壓泵底下漏油油Oil leak at the base of the Nachi hydraulic pump檢查密封圈檢查密封圈, 必要時(shí)更必要時(shí)更換換 Check gasket, replace if needed保養(yǎng)人員保養(yǎng)人員 Maint. 5/13/918 - 43 2008 TB

59、M Consulting Group, Inc. All Rights Reserved.P SKB目的目的 Used To: 發(fā)現(xiàn)所有浪費(fèi)跡象發(fā)現(xiàn)所有浪費(fèi)跡象, 提出可能解決方案提出可能解決方案Capture waste information and potential solutions 按問(wèn)題清晰程度及實(shí)施難易程度按問(wèn)題清晰程度及實(shí)施難易程度, 將解決方案進(jìn)將解決方案進(jìn)行排序行排序Rate / rank the solutions in regards to resolution of the issues and ease of implementation 8 - 44 2008

60、TBM Consulting Group, Inc. All Rights Reserved.P SKBProcess:Communications Tech Support Call ProcessBarrier / WasteRoot CauseSolution / ImpactDifficultyImpact1172473474175110647717841091710771177127413101014101015107Call ProcessingComputer System TrainingOne on one trainingParts ProcessingNo quick reference materialsNo access to ImpromptuNo S