Total Productive Maintenance OFFICE 1 Total Productive Maintenance

  • Slides: 23
Download presentation
Total Productive Maintenance OFFICE 办公室 1

Total Productive Maintenance OFFICE 办公室 1

Total Productive Maintenance ACE Office Qualifying Level 6 S TPM QCPC Market Feedback Analysis

Total Productive Maintenance ACE Office Qualifying Level 6 S TPM QCPC Market Feedback Analysis Set-Up Reduction Root Cause / Corrective Action Standard Work Mistake Proofing Process Certification Quality Clinic Activity 2

TPM 全面生产性维护 Total Productive Maintenance is an equipment management strategy that improves equipment efficiency.

TPM 全面生产性维护 Total 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! 4

TPM Key Concept TPM的重要概念 • Left neglected. . . Equipment Breaks Down • 如果不重视…设备很快就会坏

TPM Key Concept TPM的重要概念 • Left neglected. . . Equipment Breaks Down • 如果不重视…设备很快就会坏 In the past, maintenance focused on fixing equipment after it broke. 过去,维护 作总是集中在设备坏了 以后对其进行修理。 TPM’s focus is to prevent problems before equipment breaks. TPM 的焦点是要在设备出 故障以前防止问题出现。 5

Total Productive Maintenance is a New Way of Working 全面生产性维护是一种全新的 作方式 Old Attitude: 过去的态度:

Total Productive Maintenance is a New Way of Working 全面生产性维护是一种全新的 作方式 Old Attitude: 过去的态度: “I operate, you fix. ” “我操作,你修理。” “I fix, you design. ” “我处理,你设计。” “I design, you operate. ” “我设计,你操作。” TPM Attitude: TPM态度: “We are all responsible for our equipment. ” “我们所有人对我们的设备负责。” 6

Tip of the Iceberg 冰山的顶端 Failures 故障 Wear, play, slackness, leakage, dust, dirt, corrosion,

Tip of the Iceberg 冰山的顶端 Failures 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 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象。 Hidden Defects 隐藏的问题 7

Typical Causes of Equipment Breakdown 典型的设备故障原因 Failure to replace toner 更换墨盒失败 Out of paper

Typical Causes of Equipment Breakdown 典型的设备故障原因 Failure to replace toner 更换墨盒失败 Out of paper 缺纸 I wonder what’s going to fail next? 我想下面还会出什么 问题呢? Paper jam 卡纸 Component Failure 部件失灵 Dirt and contamination 灰尘和污染 8

TPM Benefits TPM的益处 • Reduced maintenance costs • 减少维护费用 – Breakdown maintenance is 10

TPM Benefits TPM的益处 • Reduced maintenance costs • 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 • Improved 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 时间,寿命更长 9

TPM Qualifying Criteria (Business Process/Office) Qualifying 3 ACE Element Awareness Training for all employees

TPM Qualifying Criteria (Business Process/Office) Qualifying 3 ACE Element Awareness Training for all employees o Equipment assessment A, B & C o PM plan for 100% of category “A” equipment What’s Ahead o BRONZE TPM CRITERIA Awareness & Baseline o Implement PM Plan o Track downtime history for vital machines o Process Management o Identify Key Processes o Identify Waste Elimination 10

Sullair Safety Lockout Program Procedure 寿力安全设备锁定计划程序 Lockout Procedures: 锁定程序: Lockout Tag: 锁定标签 Actions necessary

Sullair Safety Lockout Program Procedure 寿力安全设备锁定计划程序 Lockout Procedures: 锁定程序: Lockout Tag: 锁定标签 Actions necessary to lockout a power source of any machine to be repaired, serviced or set-up, where unexpected motion, or an electrical or other energy source, would cause personal injury or equipment damage. 在任何机器的电源需要修理、维护或准备 的地方都必须进行锁定,否则意外的动作 或其它电源将会引起人身的伤害或设备的 损坏。 12

Lockout/Tagout Review: 锁定/标识检查 WARNING 警告 • NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE. • 决不要从它人处接受锁定设备的钥匙。

Lockout/Tagout Review: 锁定/标识检查 WARNING 警告 • NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE. • 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 TAG. • 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。 13

ACTION ITEM 1: Assess All Equipment 活动内容 1:评估所有设备 • By “Equipment” we mean any

ACTION ITEM 1: Assess All Equipment 活动内容 1: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 首先放在正确的设备上。对瓶颈设备给予特殊的关注。 14

ACTION ITEM 1: Assess All Equipment (cont. ) 活动内容 1:评估所有设备(待续) ? Category A: Critical

ACTION ITEM 1: Assess All Equipment (cont. ) 活动内容 1:评估所有设备(待续) ? Category A: Critical equipment for which an alternate machine is not feasible, because: A类: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 • Category C: Equipment for which it is relatively easy to find a replacement or alternate • C类:相对容易用其它设备替代的设备 类: – 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) • Category B: All other equipment/machines • B类:所有其它设备/机器 类: 15

ACTION ITEM 1: Assess All Equipment (cont. ) 活动内容 1:评估所有设备(待续) In addition to machine

ACTION ITEM 1: Assess All Equipment (cont. ) 活动内容 1:评估所有设备(待续) In 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: – Item description/ID number 物品描述/ID号 – Category 种类 – Item Owner 物品主人 • Identify equipment’s title holder and a “local” owner if appropriate • 确定设备名义上的拥有者及一“本地”主人,如有必要的话 – Department manager’s signature – 部门经理的签名 Category A/B/C List A/B/C类清单 Item物品 ID# Category类型 Copier B 43565 Epson Printer C 3217 Air conditioner A e 7654 Personal Comp. C 4082 Personal Comp. C 3189 Personal Comp. C 2180 Personal Comp. C 2345 Title Holder名义主人 Co. Name Co. Name Local Owner本地主人 User Name User Name Department Manager 16

Example: Office Equipment Assessment Worksheet Total Productive Maintenance, Office Equipment Assessment Worksheet Note: Evaluation

Example: Office Equipment Assessment Worksheet Total Productive Maintenance, Office Equipment Assessment Worksheet Note: Evaluation for machine only. Not for networks Equipment name Dept. Equipment ID # Responsible Individual Productivity 1. How often is the equipment used each day? 2. Is there backup/alternate equipment available? 3. To what extent will a failure of this equipment affect other office processes? . Do other processes run through this equipment? 4. To what extent will a failure of this equipment affect on-time delivery? 80% or above 50 -80% 50% or below No (one of a kind) Yes (another dept. ) Yes (in dept) Stops entire dept. process Slows other dept. processes Only affects this machine Decisively Somewhat Not Significantly 5 3 2 5 3 1 5 4 1 5 2 1 Decisively Somewhat Not significantly 5 2 1 $1000 or more $0 - $1000 Service Contract Over 3 hours 1 - 3 hours 0 - 1 hour 5 4 2 Both answers are “yes” One answer is “yes” none are yes 5 3 0 Quality 5. How will the processes run on this equipment affect final quality of the finished product / service? Maintenance 6. What is the average monthly cost of repairs to this equipment? 7. What is the average time it takes to repair this equipment? (Help desk response, if applicable) Safety, Environment, Housekeeping 8. Do safety enhancements need to be applied? Does the equipment need a housekeeping schedule? “A” Machine: 32 -40 “B” Machine: 22 -31 “C” Machine: 21 or less Machine Category: Total Score: 17

ACTION ITEM 2: PM Plan on 100% “A” 活动内容 2:针对所有A类机器的PM计划 • Operator PM defined

ACTION ITEM 2: PM Plan on 100% “A” 活动内容 2:针对所有A类机器的PM计划 • Operator PM defined for 100% of Category A machines. • 为所有A类机器制定操作员PM q q Determine if there any “A” machines in your area 确定你的 作区域是否有A类机器 If there are, there must be a PM plan: 如果有,应有一个PM计划: q In-house 内部 q Outside Contractor 外部合约 人 Operator Preventive Maintenance Service Card Machine: Okuma LC-30, 4 Axis, BT # 3054 Daily PM Tasks 1. Check running 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 air 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 air filter. 4. Change air filter: Cat. # 021183. Rev: B Revision Date: 3/25/98 19

ACTION ITEM 2: PM Schedule on 50% A&B(cont’d) 活动内容 2:针对 50%A和B类机器的PM进度表(待续) Following is highly

ACTION ITEM 2: PM Schedule on 50% A&B(cont’d) 活动内容 2:针对 50%A和B类机器的PM进度表(待续) Following is highly recommended to make Operator PM effective: 强烈推荐跟进以确保操作员PM的实施: Use a “Visible at-a-glance” system (Such as a color-coded PM Status board) within the work area to indicate the actual status of “Operator PM” tasks. 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 l Must be easy to understand l No book or folder to read l 必须容易理解 l 无需翻书或文件夹 20

What is next? 下一步是什么? Complete TPM training of your work group by March 7,

What is next? 下一步是什么? Complete TPM training of your work group by March 7, 2001年 3月7日前你的 作组应 完成TPM培训 Before the end of February, look for a groupwise announcement of a “Driver’s” Meeting to discuss the necessary resources and logistics for completing qualifying TPM activities 在 2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活动 21

Summary 小结 We want a company that reveres people who design, build and maintain

Summary 小结 We want a company that reveres people who design, build and maintain things that never break, rather than people who fix things that break. George David UTC Chairman and CEO 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。 George David UTC Chairman and CEO 22

Total Productive Maintenance OFFICE 办公室 23

Total Productive Maintenance OFFICE 办公室 23