第六章 全面生產維護

TotalProductiveMaintenance(TPM)

全面生產維護（TPM）TPM–DefinitionTotalProductiveMaintenance(TPM)isamanufacturinginitiativeforoptimizingtheeffectivenessofequipment全面生產維護（TPM）是制造過程中優(yōu)化設備效率的管理方法FiveComponentsofTPM

TPM的5個組成部分Maintenanceprevention:design/selectionofthemachineforoptimumperformanceandlife1.保養(yǎng)預防：設計/選擇機器優(yōu)化性能和壽命2.Predictivemaintenance:predictingthelifeofcriticalmachinecomponentsandreplacingthem2.預測性維護：預測關鍵設備零部件的壽命并更換它們Correctivemaintenance:improvingtheequipment’sdesign/systemstogetbetterperformance3.校正性維護：改善機器的設計/系統(tǒng)以獲得更佳的性能Preventivemaintenance:throughplannedmaintenanceactivitiesensuringcontinuous,smoothperformance4.預防性維護：通過計劃維護工作確保持續(xù)的、平穩(wěn)的性能Autonomousmaintenance:employeeownedcompletemaintenanceprogram5.自主維護：職工擁有完全的維護程序5.AutonomousMaintenance

5.自主維護Objective:makethemachineoperatorthe“firstlineofdefense”,throughtrainingandempowermenttoensureregularcleaning,lubrication,inspectionsandtotalownershipthatachievescontinuousimprovementinequipmenteffectiveness目的：通過培訓和授權讓機器的操作者成為“第一道防線”，確保定期的清掃、潤滑、檢查和全部所有權，以獲得設備效率的持續(xù)改進。Autonomousmaintenanceisself-governing,self-ruling,non-centralizedmachinemaintenanceprogram自主維護是一種自我管理、自我控制、非集中的機器維護程序。Requiresthebiggestchangeinattitudesofall需要下列人員在態(tài)度上發(fā)上極大的改變：Management,maintenancetechnicians,machineoperators,engineers管理人員、維護技術員、機器操作者、工程師WhyAutonomous?

為什么是自主的？Operators操作者Spendthemosttimewiththemachines其與機器度過大多數(shù)時間CANandWILLnoticetheabnormalitiesfirst能夠并且會第一時間注意到異?，F(xiàn)象Havethemostuniqueknowledgeofthemachine,it’spartsandit’sfunctioning對機器、其零件和功能擁有大多數(shù)獨一無二的知識Havemuchcloseremotionalattachmentwith,andsenseofownershipofthemachines對機器有主人翁責任感，具有更為親近的感情Livelihooddependsmoredirectlyonthemachineinquestion其生活更直接地依賴于所述的機器Aremostlytechnicallyinclined主要是傾向于技術WhyAutonomous?

為什么是自主的？“someonewhoisdrivingacardailywillnoticeafaultyfront-endalignmentmuchsoonerthanthemechanicwholooksatitoccasionally”“每天都開車的人將會比一位只是偶爾查看這輛車的技師更早注意到有缺”WhatIsTPM?Optimizeeffectivenessofmachinesby通過下列工作優(yōu)化機器的效率：Focusingonentirelifeofthemachine關注機器的全部使用年限Involvingallthecontributorsthroughactiveparticipationandteaming通過主動參與和組成團隊，涉及到所有有貢獻的人Makingtheoperatorsthefirstlineofdefenseagainstdeterioration,throughAutonomousMaintenance通過自主維護，使操作者成為防止機器退化的第一道防線SettingthegoalofZeroLosses設定零損失的目標InOtherWords….Doeverythingpossibletomakesurethemachinekeepsmakinggoodqualityparts,atthedesiredproductionrate,everytimeyouwantitto盡可能做好每一件事情，確保機器在你要求的每時每刻按照要求的生產速度持續(xù)不斷的生產優(yōu)質零件OR或者Zerobreakdowns零故障 Zerodefects零缺陷 Zerolossesduetosetups 調試造成的損失為零Zeroaccidents 零事故 Zeroleaks零泄漏 SevenStepsof

TotalProductiveMaintenancePerforminitialcleaning&inspection實施初始清掃&檢查Eliminatecausesofcontamination&inaccessibleareas消除污染源和不可接近的區(qū)域Developcleaning,lubricating,andinspectionstandards制定清掃、潤滑和檢查標準Providebasictraininginmachine’sfunctionandcontrols,toenableeffectivegeneralinspection提供關于機器功能和控制的基本培訓，使其能夠行使有效的全面檢查Enhanceandimplementautonomousinspectionstandards&schedules提高并執(zhí)行自主檢查標準&時間進度表Implementworkplaceorganization&housekeeping,employing5S&visualcontrols運用5S和可視控制貫徹執(zhí)行工作場所組織&內務管理Followuponalltheabovestepsandadvancedimprovementactivities遵守上述全部步驟和預先的改進工作TPMStatusWheel

TPM狀態(tài)輪StagesofTPMEquipmentEffectiveness設備的效率Time時間RestorationTPM重建TPMSustainingTPM持續(xù)的TPMUsefulLifeofEquipment設備的使用年限TPMSteps4-7TPM的第四步至第七步InitialTPMKaizenEvent初始的TPM改善活動TPMSteps1,2,3TPM的第一、二、三步RestoretheMachinePrepareforSustainingSustainSevenStepsof

TotalProductiveMaintenancePerforminitialcleaning&inspection實施初始清掃&檢查Eliminatecausesofcontamination&inaccessibleareas消除污染源和不可接近的區(qū)域Developcleaning,lubricating,andinspectionstandards制定清掃、潤滑和檢查標準Providebasictraininginmachine’sfunctionandcontrols,toenableeffectivegeneralinspection提供關于機器功能和控制的基本培訓，使其能夠行使有效的全面檢查Enhanceandimplementautonomousinspectionstandards&schedules提高并執(zhí)行自主檢查標準&時間進度表Implementworkplaceorganization&housekeeping,employing5S&visualcontrols運用5S和可視控制貫徹執(zhí)行工作場所組織&內務管理Followuponalltheabovestepsandadvancedimprovementactivities遵守上述全部步驟和預先的改進工作ObjectivesofStep1Cleantheentiremachine–insideandout清掃整臺機器——內部和外部Inspectforproblems,abnormalitiesanywhereinthemachine檢查機器是否存在問題和異常現(xiàn)象Identifyopportunitiesforimprovements/enhancementstotheoriginaldesign確認對初始設計的改進/提高機會Identifytheroutinecleaning&inspectionneeds確認日常的清掃&檢查需要Operators&maintenancepersonnellearn操作員&維護人員知曉下列事項Howtothoroughlyclean&inspectwhilecleaning在清掃時，怎樣徹底清掃&檢查Howtoidentifyproblems,abnormalities怎樣確認存在的問題和異?，F(xiàn)象Todevelopstandardsforroutineactivities制定日常工作標準Cleaning

清掃Cleanalltheoutsidesurfacestouncoverabnormalities清掃所有的外表面以發(fā)現(xiàn)異?，F(xiàn)象Disassembleallthesystemsandcomponentstothoroughlycleanandinspecteverycomponent拆卸所有的系統(tǒng)和零部件，對每個零部件進行徹底的清掃和檢查Removealltheauxiliarysystemsandcomponentstoclean&identifyopportunitiesforimprovements拆除所有的輔助系統(tǒng)和零部件進行清掃&確認改進的機會Pressurewash(withhotwater)allthecomponents（使用熱水）壓力清洗所有的零部件Prepareappropriatesurfacesforrepainting適當?shù)谋砻嬷匦峦科酻nderstandwhichpartsofthemachineneedtobecleanedonaroutinebasisandhowoften了解機器的哪些零件需要日常清掃以及清掃的頻率Inspections檢查Lookforleakageof檢查下列事項是否存在滲漏Lubricants,coolants,hydraulicfluids,air潤滑器、冷卻劑、液壓油、空氣Checktheconditionof檢查下列事項的狀況Belts,chains,couplings,motors,gearboxes,etc.傳動帶、傳動鏈、連接、發(fā)動機、齒輪箱等Electricalpneumatic,hydraulicandcoolantsystemcomponents電氣、液壓和冷卻系統(tǒng)零部件Allthefasteners所有大緊固器Alltypesoffilters,valves,regulators,gages,indicators,etc.所有類型的過濾器、閥、調節(jié)器、量具、指示器等Lookfor查找Excessivevibrations,noise,heat過度的振動、過度的噪音、過熱Lookfor查找Excessive,insufficient,orlackoflubrication潤滑過度、潤滑不足，或者缺少潤滑Abnormalities異?，F(xiàn)象Anythingthatispresentwhereitdoesnotbelong出現(xiàn)的任何不屬于下列事物的事項Coolant,oil,grease,chips,swarf冷卻劑、油、潤滑脂、碎屑、細鐵屑Tools,accessories,setupparts,productionparts,etc.工具、附件、安裝零件、生產零件等Coffeecups,rags,papers,drawings,Kanbancards,etc.咖啡杯、地毯、紙張、圖紙、看板卡等Anythingthatisabsentthatshouldbepresent應該出現(xiàn)而缺少的事項Lubricants,fasteners,guards,covers,brackets,etc.潤滑劑、緊固器、防護罩、端蓋、支架等Worn,broken,missing,malfunctioningparts/systems磨損、破碎、丟失、不正常工作的零件/系統(tǒng)Wearonslidingsurfaces滑動表面的磨損Play,looseness,sagging,excessivemovements游隙、松動、下垂、過度運動Warpage,deformation,misalignments翹曲、變形、未校準Rustorsurfacedamage生銹或表面損壞Odor,stains,discolorationofanyliquids液體的臭味、污點和變色Lubrication–OilingSystems潤滑——上油系統(tǒng)Identifysourcesofleakage確認滲漏源Emptyandcleanthetank,andallthelines倒空并清掃油槽及整個管路Cleanorreplacefilters清掃或更換過濾器Makesurelubricationlinesarenotdamagedorclogged確保潤滑管路沒有遭到損壞或堵塞Verifythatallpointsarereceivingoil,inproperquantity驗證所有的潤滑點均受到適量潤滑油的潤滑Makesurepressurizingsystemisworkingproperly確保加壓系統(tǒng)正常工作Makesureallthegages,indicatorsareworking確保所有的量具、指示器均在工作Considerappropriatenessoftheirlocation考慮它們位置的適當性Getre-circulatingoilanalyzedtouncovercontamination,over-heating,spoilageandcauses獲取再循環(huán)潤滑油以發(fā)現(xiàn)污染、過熱、損壞及其起因Verifyappropriatenessofthelubricantsused校驗所使用的潤滑劑的適當性ObjectivesofStep2

第二步的目的Preventaccelerateddeteriorationbystoppingthecontaminantsattheirsource&preventintroductionofcontamination從源頭上阻止污染物，以及防止污染的進入防止加速損壞Learnaboutequipmentimprovementactivities了解設備改進工作Makethoroughcleaningandinspectioneasierandlesstime-consuming使全面的清掃和檢查工作更易于進行并節(jié)省時間Focusonobstaclestoeffectivecleaning&inspection集中精力于那些有效清掃&檢查的障礙Encourageoperatorstousetheircreativitytocontrolequipmentandtheenvironmental鼓勵操作員運用他們的創(chuàng)造性來控制設備和環(huán)境Encourageproactiveapproach鼓勵主動方法ObjectivesofStep2Eliminateallthedrippans消滅所有的承油盤TypicalContaminants

典型的污染物Leakageorsplatteringoflubricationorhydraulicoils,grease,coolant,water,air,otherliquids潤滑油或液壓油、潤滑脂、冷卻劑、水、空氣、其它液體滲漏Cuttingchips,grindingswarf,drygrindingpowder,punchedsheetmetalpieces,cuttingorweldingsplatters,spraypaint,moldingflash,looseburrs,sandfromcastings切屑碎屑、研磨碎屑、干的研磨粉、沖下的金屬碎片、切屑或焊接飛濺物、噴漆、模制飛邊、沒有約束的飛邊、鑄造產生的砂子Otherforeignmatters–dust,packingmaterial,mist,moisture,smallcomponents,brokenparts,fasteners,excessglueoradhesives其它異物——灰塵、包裝材料、煙霧、濕氣、小部件、破損的零件、緊固器、過量的膠水和粘結劑EliminatingContamination

消除污染Repairleaks,preventoverflows維修滲漏，防止溢流Reduce/controlflowofallthefluids減少/控制所有液體的流出Installshieldsandcoverstocontaincuttingdebris安裝防護罩和端蓋容納切屑碎片Containthedebristoassmallspaceaspossible容納碎片的空間越小越好Installdirtanddebriscollectors安裝灰塵和碎片收集器Automaticchips/swarfconveyingsystems自動的碎屑/切削屑輸送系統(tǒng)Poweredmistanddustcollectorsformachines為機器安裝有動力裝置的煙霧和灰塵收集器Usevacuuminsteadofpressurizedairforcleaning進行清掃工作時，使用真空吸塵器替代壓縮空氣Deviseefficientcleaningandwashingmethods設計高效的清掃和清洗方法Considerreplacingalltheseals,wipers,fasteners,bearings,andotherlowcostspares考慮更換所有的密封、墊圈、緊固器、軸承和其它低成本備件CausesofInaccessibility不可接近的起因

HiddenLocations隱藏的位置Behindthemachine,behindthecovers處在機器的背后、端蓋的背后Obscuredbyotherparts,hoses,pipes,cables,controlpanels,auxiliaryequipment被其它零件、軟管、電纜、控制面板、附屬設備所遮蔽Obscuredbystoragecabinets,partsstorage,othermachines,etc.被儲藏室、零件倉庫、其它機器等所遮蔽Coveredupbychips,swarf,dust,paint,etc.被碎屑、切削屑、灰塵、油漆等所覆蓋Movingpartshavetobealignedinacertainway運動零件必需以某種方式校直CausesofInaccessibility不可接近的起因

DifficultLocations不利的位置Exposuretoinjuryorhazards,suchaschipsorsharpobjects暴露于受傷害或危險之中，例如碎屑或尖銳的物體Exposuretoslippinghazards,suchasoilyorwetfloors暴露于滑倒的危險之中，例如含油的或潮濕的地面Possibilityofexposuretoelectricshock,highpressure,hightemperature有暴露于電擊、高壓、高溫的可能性Highupfromthefloorortooclosetothefloor距離地面過高，或距離地面過近Smallpassageforoperatororhandsortools對于操作者或手或工具來講，過小的過道ImprovingAccessibility提高接近性Repositiongages,indicators,lubricationpoints量具、指示器、潤滑點復位Installconsolidatedlubricationsystems安裝統(tǒng)一的潤滑系統(tǒng)Reroutepipes,hoses,cables管路、軟管、電纜重新布線Avoidflexiblehosesandcableswhereverpossible盡可能的避免使用有彈性的軟管和電纜Addtransparentwindowsoncovers在端蓋上添加透明的窗戶PolycarbonateorLexan聚碳酸脂或勒克森Simplifycovermountingsforquickremoval簡化端蓋安裝，便于快速拆除Removedrippansandplatforms拆除承油盤和平臺Providesufficientspacebetweenmachines機器之間有足夠的間隙TargetsforImprovement

改進的目標Machinepartsthatgetdirtysoonafterthoroughcleaning在徹底清洗后很快就變臟的機器零件Timespentinroutinecleaningisdisproportionatelyhigh花費在常規(guī)清掃上的時間不成比例的高Keypartsofmachinethatarehardorimpossibletocleanandinspect機器的關鍵零件難以或不可能進行清掃和檢查Cleaningorinspectionishazardous清掃或檢查工作時是危險的ObjectivesofStep3Capturetheknowledgeandunderstandingacquiredbytheoperatorsandmaintenancetechnicians獲取作為操作員和維護技術于所需的知識和認識Developprovisionalstandardsforcleaning,inspectionandlubrication制定清掃、檢查和潤滑的臨時標準Organizetheworkarea&machineandplacevisualcontrolstohelpfollowstandardsefficiently組織工作區(qū)/機器和場地視覺控制，幫助有效地遵守標準Organizecleaningandlubricationsupplies,tools,etc.組織清掃和潤滑供應品、工具等Beginimplementingthepracticesthatwillhelpmaintainequipment’sconditionachievedinsteps1and2開始實施那些有助于維護設備在步驟1和步驟2中取得的狀態(tài)的實踐ProvisionalCleaningStandards臨時清掃標準CleaningstandardsshouldInclude清掃標準應該包括：Areas/parts/systemstoclean要進行清掃的區(qū)域/零件/系統(tǒng)Scheduleforcleaning清掃的時間進度表Methodofcleaningandtoolstobeused將要采用的清掃方法和工具Acceptancecriteriaforcleanliness清掃工作的驗收標準Organizethecleaningsupplies,placeconvenientlyandlabelthem組織清掃用品，放置到方便的位置，并為它們加上標簽Makeassignmentsamongtheoperators在操作員之間分派工作Tryoutthestandardsandtimethem試用該標準并為其定時Identifyopportunitiesandneedsforimprovements確認改進的機會和需要GuidelinesforProvisionalStandards臨時標準指導原則Standardsmustbedevelopedbytheteamwithveryactiveparticipationoftheoperators標準必需由團隊制定，并有操作員的積極參與Non-participatingoperatorsofthemachinemustreviewprovisionalstandardsbeforeimplementation沒有參與其中的機器操作員必需在實施之前審查臨時標準Listthetasksinalogical,efficientsequence按照邏輯的、有效的順序列出工作任務Standardsshouldbeclearandeasytounderstand標準應該是清楚的、易懂的Labelsonthemachineandchecklistsmustmatch機器上的標簽和檢查單必需相配比Tryoutthestandardsto使用該標準Verifyappropriatenessandsafetyofthetasks校驗任務的適合性與安全性Verifyoperatorcapabilityandskills校驗操作者的能力和技術Timeeachtasktoidentifyimprovementopportunities為每項任務定時以確認改進機會ObjectivesofStep4Enhanceoperator’sknowledge&skillsrelatedtoequipment’soperation,systemsandcomponents提高操作者對設備操作、系統(tǒng)和零部件有關的知識和技能Improveinspectionanddiagnosticskills提高檢查和診斷的技能Expandthescopeofroutineinspectionperformedbytheoperators擴展由操作人員履行的日常檢查工作的范圍Promotecontinuousimprovementthroughcorrective&predictivemaintenance通過糾正&預先維護工作激勵持續(xù)的改進Makesurethereisacommon“l(fā)anguage”andterminologythroughouttheorganization確保在整個組織中使用通用的“語言”和術語ActivitiesDuringStep4Identifytrainingtopics確認培訓的主題Identify/developtrainingmaterialandmethods確認/制定培訓材料和方法Evaluatethepotentialtrainerresourcesandselect評價潛在的培訓師資源并作出選擇Developamasterplanfortrainingdelivery為培訓交付制定一個總體規(guī)劃Providethetraining提供培訓Evaluatethetrainingperformanceandmakenecessarychanges評價培訓成績，并作出必要的改變Periodicallyreevaluatethetrainingneeds周期性地重新評價培訓需要Includeappropriatetopicsinnewemployeetraining在新員工培訓中包含適當?shù)闹黝}ExpectedOutcomeofIndividualTraining

個體培訓期望得到的結果Operatorsunderstandthespecificsysteminvolvedinthemachineandit’sfunction操作者理解包括在機器中的特定系統(tǒng)及其功能Operatorscanidentifykeycomponentsofthesystemandtheirfunctions操作者能夠辨別系統(tǒng)的關鍵零部件及其功能Operatorscancleanandinspectthesystemandallthecomponents操作者能夠清掃并檢查系統(tǒng)及所有零部件Operatorsbecomeawareofcommonlyoccurringproblemsandrecognizesymptomsofmalfunction操作者開始了解通常情況下發(fā)生的問題，能夠認出故障的現(xiàn)象Becomeawareofimmediateactionstobetaken,inasafemanner,whenabnormalitiesareidentified當確認發(fā)生異常情況時，知曉以安全的方式立即采取的行動Explainthesymptomstomaintenancetechnicians向維護工程師說明現(xiàn)象Operatorscanthinkofimprovementopportunitiesandideas操作者能夠考慮到改進機會和想法ObjectivesofStep5

第五步的目的Updateandfinalizetheprovisionalstandardsdevelopedduringstep3更新并最終確定第三步中制定的臨時標準maintenanceandaudits維護和審查Developandinstitutionalizeimprovement/updateprocessforthestandards制定標準的改進/更新程序，并使其制度化Combinecleaning,lubrication,andinspectiontasksinto“unifiedautonomousmaintenancestandards”使清掃、潤滑和檢查工作聯(lián)合成為“統(tǒng)一的自主維護標準”Substantiallyreducethetimetakenforcleaning,lubricationandinspectionactivities大量減少進行清掃、潤滑和檢查工作所需的時間ObjectivesofStep6

第六步的目的Maintaintheareasurroundingthemachinecleanandorganized,atalltimes,tosupportthedisciplinedTPMactivities保持機器周圍區(qū)域干凈整齊，總是支持培訓過的TPM工作Implementandsustain5S貫徹并支持5SAnenvironmentthatissafe安全的環(huán)境Asurroundingthathelpsefficientworking有助于高效工作的環(huán)境“Visualworkplace”thathelpsavoidmistakesandhelpstrainnewemployeeseasily有助于避免發(fā)生錯誤、協(xié)助培訓新員工工作的順利進行的“可視的工作場所”Promoteasenseofownershipandprideintheworkplace在工作場所鼓勵主人翁責任感和自豪感VisualWorkplaceVisualWorkplaceisaworkplacewhereproactivedisplayofallthenecessaryinformationthathelpsavoidmistakesandprovidesstatusataglance可視的工作場所可以預先展示全部必要信息，這有助于避免發(fā)生錯誤，并且看一眼就知道現(xiàn)場的狀態(tài)Typicalinformationdisplayedvisually視覺上展示的典型信息Businessgoals,values,“dosanddon’ts”工作目標、價值觀、應該做的和不應該做的Real-timeproductiontargetsandactualproduction實事的生產目標和實際產量Workinstructions,schedulesandassignments工作指示、時間進度表和分配Boundariesandindicationsoflocations工作場所的界限和標志Qualityresultsandtrends質量結果和趨勢Specialprojects/teamsmessages,goals,achievements,etc.特殊的項目/團隊信息、目標、取得的成績等VisualsforTPMTPMTeam’sstoryboardTPM團隊的描述板Alltheinfoontheproject,plans,achievedresults,etc.關于項目的全部信息、計劃、取得的成績等TPMStandards,schedules,assignmentsandreal-timestatusupdateTPM標準、時間進度表、工作分配和實時狀態(tài)更新Instructionsforsafeoperationsandwarnings安全操作說明和警告Instructionsforinspectionandlubricationactivities檢查和潤滑工作說明Locationmarkingsofeveryneedediteminthearea區(qū)域內每項必需項目的位置標識Markingstohighlightnormalandabnormalconditions非常正常和