一份老外的TPM讲义
合集下载
TMP讲义
• Focused Improvement 个别改善 (KAIZEN)
• Planned Maintenance 计划维护 • Quality System Maintenance 质量系统维护 • Supply Chain / Office TPM 供应链/办公室TPM • Equipment Early Management 设备早期管理
• Planned Maintenance 计划维护 (PM)
• Predictive Maintenance 预测维护 (PM) • Plant Maintenance / Process Maintenance 生产制造维护 (PM)
Productive Maintenance
生产/生产力维护
TPM的发展历史
TPM目标的制定
• Cost 成本
- Conversion cost per ton 制造成本 - Repair & maintenance cost / capital employed (CRV) or Repair & maintenance cost as % of conversion cost 维修成本占资产或制造成本的比例 - Spare parts value 备件量 - Budget for TPM vs. TPM savings TPM 投入和节约对比 - Cost of quality issues 质量问题的成本 - Energy cost / ton 能源消耗 - Raw/packaging material waste (% of cost/ton) 原材料和包材的浪费 • Delivery 交货期 - On time in full , case fill 按时交货率 - Conformance to plan (% of SKUs) 计划完成率 - Stock of raw/packaging material (weeks cover) 原材料和包材的库存 - Stock of finished product (weeks cover) 产品的库存 - Work in process (tons) 在线生产量
TPM讲义教材[1]
![TPM讲义教材[1]](https://img.taocdn.com/s3/m/cff34fdfc77da26925c5b091.png)
設备的改善 营运的系統化
保养组织的效率化
操作失误的防止 設备清扫的实施 日常点检的实施 定期点检的实施 故障解析的实施 保养计划的确立
修理整备技能提升 预防保养的实施
改良保养的实施
润滑管理
预备品的管理
TPM讲义教材[1]
. 自主保全和专门保全的技能分担
目标
设 备 综 合 效 率 90 以 上
PPT文档演模板
PPT文档演模板
TPM讲义教材[1]
故障的分类及损失结构
损失
结果 故障,停止损失 P 小停止损失 Q 换工程调整损失 C 速度低下损失 D 性能低下损失 S 成品不良损失 M 保养费用损失
人员过剩损失 灾害发生损失
P:生产量 C:成 本 S:安 全
Q:品 质 D:交货期 M:士 气
----------致命故障 MTBF ---------长时间故障 分析 --------- 一般故障
2)测定老化的活动(主要依据 5感) •日常点检 •定期点检的一部分
3)恢复老化的活动 •小整备(简单的部品交换,异常时的应急措施) •故障,其它缺陷发生时迅速正确的联络 •突发修理的援助
PPT文档演模板
TPM讲义教材[1]
. 保全部门的作用
1) 本来业务的保全活动 •以老化测定和老化复原为中心的活动和定期保全,预知保全,改良保全等相比 是技术, 技能要求领域的主力
2) 运转部门的自主保全活动支援 •设备的机能,构造,部品名称,不分解的话就不能进行不好部位的重点指导 •螺丝,折叶等的连接处的相关教育指导 •润滑,油料种类的统一,加油基准的作成指导 (加油介绍,油种,周期) •点检技能的教育指导,点检技能的作成指导(POINT,周期) •老化,基本条件,缺陷等不合理工程的迅速处理 •发生源,困难改小对策,效率化等改善活动的技术援助 •日日活动(对于现场,现物会议,保全等邀请事项的听取)实践
全面生产维护(TPM)讲义
❖ 1）设备购置时选型有误。过多地考虑技术储备，盲 目追求加工中心的兼容性，结果是在用精密机床加工 非精密、低附加值和低效率的零件，导致部分功能闲 置。
❖ 2）相关的工艺装备不配套。在刀具、夹具、量具、 软件、维修和环境等方面的投资不足，造成机床使用 的寿命和效率的低下。
❖ 3）工艺编排不合理。没有根据精益生产的“一个流” 去编排产品加工的工艺过程，只是根据设备的种类编 组，在某一工步或工序节省了部分时间，而没有从根 本上提高效率。
投资或员工的加班加点也就是资源的投入实现的。但是这种资源投入型
的生产方式由于固定成本的增加并不能有效提高企业生产经营的效益，
同时这种粗放型的生产方式也不利于资源的节约和环境保护。
❖ 现代设备管理的理念是通过加强设备管理，提高设备的综合效率以 实现生产能力的提高。因为生产设备综合效率的提高可以减少各种形式 的设备非计划停机时间，从而实现提高设备生产能力的目标。
❖ 为了解决这些问题，美国等制造业提出了“事后维 修（Breakdown Maintenance ，BM）”，即当装 备出现故障后马上采取应急措施进行事后处置。
❖ 这一时期，设备最显著的特点是半自动、手动操作 设备多，结构也简单，因此工人可以自己动手修理， 现象是不坏不修、坏了再修。
❖ BM从上世纪初一直持续到40 年代。
❖ （2）预防维修
❖ 上世纪50年以后，开始出现复杂设备，复杂设备由大 量零件组成，修理所占用的时间已成为影响生产的一 个重要因素。
❖ 另外，人们发现设备故障总在某个部位出现，因此在 维护时主要去查找薄弱部位并对其进行改良。
❖ 为了尽量减少设备修理对生产的影响，苏联提出计划 维修制度；美国提出预防维修制度，即PM （Preventive Maintenance / 1951 ) ，即通过对设 备的“物理性检查”预防其故障的发生，从而达到延 长设备使用寿命的目的。
❖ 2）相关的工艺装备不配套。在刀具、夹具、量具、 软件、维修和环境等方面的投资不足，造成机床使用 的寿命和效率的低下。
❖ 3）工艺编排不合理。没有根据精益生产的“一个流” 去编排产品加工的工艺过程，只是根据设备的种类编 组，在某一工步或工序节省了部分时间，而没有从根 本上提高效率。
投资或员工的加班加点也就是资源的投入实现的。但是这种资源投入型
的生产方式由于固定成本的增加并不能有效提高企业生产经营的效益，
同时这种粗放型的生产方式也不利于资源的节约和环境保护。
❖ 现代设备管理的理念是通过加强设备管理，提高设备的综合效率以 实现生产能力的提高。因为生产设备综合效率的提高可以减少各种形式 的设备非计划停机时间，从而实现提高设备生产能力的目标。
❖ 为了解决这些问题，美国等制造业提出了“事后维 修（Breakdown Maintenance ，BM）”，即当装 备出现故障后马上采取应急措施进行事后处置。
❖ 这一时期，设备最显著的特点是半自动、手动操作 设备多，结构也简单，因此工人可以自己动手修理， 现象是不坏不修、坏了再修。
❖ BM从上世纪初一直持续到40 年代。
❖ （2）预防维修
❖ 上世纪50年以后，开始出现复杂设备，复杂设备由大 量零件组成，修理所占用的时间已成为影响生产的一 个重要因素。
❖ 另外，人们发现设备故障总在某个部位出现，因此在 维护时主要去查找薄弱部位并对其进行改良。
❖ 为了尽量减少设备修理对生产的影响，苏联提出计划 维修制度；美国提出预防维修制度，即PM （Preventive Maintenance / 1951 ) ，即通过对设 备的“物理性检查”预防其故障的发生，从而达到延 长设备使用寿命的目的。
TPM培训讲义课件
01
根据生产需求，明确设备应具备的功能、性能参数及技术要求
。
设计方案评估与优化
02
对设备设计方案进行全面评估，确保满足生产需求、降低成本
、提高可靠性。
设备布局与配套设施规划
03
合理规划设备布局，确保设备安全、高效运行；同时考虑配套
设施如电力、气源、排水等。
设备采购、安装及调试流程
01
02
03
设备采购
按照预防性维护计划，对设备进行定期检查、保养、更换易损件等 活动，防止设备故障发生。
建立检查记录与档案
对每次检查、保养、维修等活动进行记录，建立设备档案，方便后 续管理和维护。
03
CATALOGUE
计划保全与故障排除技巧
计划保全策略制定及实施步骤
设备状况评估
定期检查设备运行状态，收集 设备运行数据，评估设备性能
确定团队领导及核心成 员角色定位
建立有效的团队协作与 沟通机制
设定团队目标与工作计 划
培训需求分析和课程体系设计
01
02
03
04
调研分析员工技能现状及培训 需求
制定针对不同岗位和层级的培 训课程
设计符合TPM理念的课程体 系架构
评估课程效果并持续优化更新
内部讲师选拔培养及激励机制
制定内部讲师选拔标准与流程
01
02
03
04
维修流程梳理
对设备维修流程进行全面梳理 ，明确各环节职责及工作要求
。
维修效率提升措施
制定并实施维修效率提升措施 ，如采用快速维修工具、优化
维修步骤等。
维修人员培训
加强维修人员技能培训，提高 维修效率和质量。
维修备件管理
一份老外的tpm讲义.ppt
source: K. Shirose, TPM For Workshop Leaders, p. 10
7
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
5
Total Productive Maintenance
What it is:
1. Optimizes equipment efficiency 2. Implements a company wide Preventive Maintenance system 3. Involves production equipment designers, operators, and maintenance
Lecture notes Participant manual
2
Table of Contents
Executive Overview
Session 1.0 Session 2.0 Session 3.0 Session 4.0 Session 5.0
Introduction……………………………………...3
* High safety risk tasks
* Basic adjustments
20
Maintenance Task Allocation between Production and Maintenance
7
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
5
Total Productive Maintenance
What it is:
1. Optimizes equipment efficiency 2. Implements a company wide Preventive Maintenance system 3. Involves production equipment designers, operators, and maintenance
Lecture notes Participant manual
2
Table of Contents
Executive Overview
Session 1.0 Session 2.0 Session 3.0 Session 4.0 Session 5.0
Introduction……………………………………...3
* High safety risk tasks
* Basic adjustments
20
Maintenance Task Allocation between Production and Maintenance
{选篇}一份老外的TPM讲义 ln
2
Table of Contents
Executive Overview
Session 1.0 Session 2.0 Session 3.0 Session 4.0 Session 5.0
Introduction……………………………………...3
Role in Lean Manufacturing…………………….8
Role of the Operator in TPM…………………..18
Autonomous Maintenance Implementation……22 Equipment Performance: Measurement & Management………………….56
3
Total Productive Maintenance
一份老外的TPM讲义
Performance Excellence Series Training Module Elements
Executive Overview Lecture notes
Knowledge Breakthrough
Tools Workbook
Lecture notes Participant manual
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
TPM——讲义PPT课件
•2020/3/28
•29
2 自主保养step2导入推动 哲理小故事
•小蜗牛：为什么我们从生下来，就要背负这个又重又硬的壳呢？ •妈妈：因为我们的身体没有骨骼的支撑，只能爬，又爬不快，所以
要这个壳的保护！
•小蜗牛：毛虫姐姐没有骨头，也爬不快，为什么她不用背这壳呢？ •妈妈：因为毛虫姐姐能变成蝴蝶，天空会保护她啊。
2 -原因
表
文件中所有带有“为什么”的语句都3 -为会什么定? 义真正的3根-原源因 （通常需要至少5个“为什么”）
4 -为什么?
4 -原因
5 -为什么?
5 –根源
•2020/3/28
•35
2 自主保养step2导入推动
5Why质量工具简介
注意!!!
五个为什么
问五次为什么
5
•2020/3/28
•36
•2020/3/28
•8
1 TPM基础概念回顾
“一套三表”的概念
何谓“一套三表”？
《自主保养暂定基准书》----岗位操作员每月例行常规保养项目标准
《自主保养查检表》--------依照《自主保养暂定基准书》的执行记 录
《不良点标签汇总表》------执行保养的过程中发现异常（不良点） 记录，
并追踪复原、改善
奇怪为什麽?每周都要 换 O型密封圈。
换上一个 O型密封圈， 再换上一个活塞杆。
•2020/3/28
•20
2 自主保养step2导入推动
一个月之后，汽缸又
开 始漏油。
为什么 活塞杆
又
损坏，认真观察发现是
工
•2020/3/28
•21
2 自主保养step2导入推动
换上一个 O型密封圈， 再换上一个活塞杆， 加上一个盖子。
一份老外的TPM讲义
source: K. Shirose, TPM For Workshop Leaders, p. 10
7
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
19
Division of Maintenance Duties between Production and Maintenance
Depending on knowledge and skills required, responsibility for equipment maintenance tasks needs to be defined:
Without TPM
Operation
MED & Industrial Engineering
The operator operates, maintenance maintains, etc.
Maintenance
With TPM
Operation
MED & Industrial Engineering
Typical success results after implementation of TPM: Breakdowns: 1/30 to 1/100 of prior level Machine defects: 1/30 to 1/40 of prior level Productivity: 30 - 100 percent increase
7
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
19
Division of Maintenance Duties between Production and Maintenance
Depending on knowledge and skills required, responsibility for equipment maintenance tasks needs to be defined:
Without TPM
Operation
MED & Industrial Engineering
The operator operates, maintenance maintains, etc.
Maintenance
With TPM
Operation
MED & Industrial Engineering
Typical success results after implementation of TPM: Breakdowns: 1/30 to 1/100 of prior level Machine defects: 1/30 to 1/40 of prior level Productivity: 30 - 100 percent increase
- 1、下载文档前请自行甄别文档内容的完整性，平台不提供额外的编辑、内容补充、找答案等附加服务。
- 2、"仅部分预览"的文档,不可在线预览部分如存在完整性等问题,可反馈申请退款(可完整预览的文档不适用该条件!)。
- 3、如文档侵犯您的权益，请联系客服反馈,我们会尽快为您处理(人工客服工作时间：9:00-18:30)。
Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management
A STRATEGY FOR PERFORMANCE EXCELLENCE
1
Performance Excellence Series Training Module Elements
Executive Overview Lecture notes
Knowledge Breakthrough
Tools Workbook
Role in Lean Manufacturing…………………….8
Role of the Operator in TPM…………………..18
Autonomous Maintenance Implementation……22 Equipment Performance: Measurement & Management………………….56
13
Early Equipment Management
Optimizes equipment selection through:
? 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.
source: K. Shirose, TPM For Workshop Leaders, p. 10
7
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
5
Total Productive Maintenance
What it is:
1. Optimizes equipment efficiency 2. Implements a company wide Preventive Maintenance system 3. Involves production equipment designers, operators, and maintenance
Without TPM
Operation
MED & Industrial Engineering
The operator operates, maintenance maintains, etc.
Maintenance
With TPM
Operation
MED & Industrial Engineering
? MP Design: activity which is focused on minimizing future maintenance costs and production losses of equipment at the design stage.
14
Total Productive Maintenance
18
Total Productive Maintenance
TPM, the total approach ? The operator is the first line caretaker ? Maintenance personnel are the specialized caretakers.
Production Operators
defined:
Maintenance Technician Production Operator
* Equipment overhaul
* Basic lubrication
* Special skill tasks
* General cles * Multi-point inspection
Maintenance
Shared responsibilities
15
Equipment Maintenance Responsibilities
Autonomous maintenance
Operation
MED & Industrial Engineering
Maintenance prevention
? 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.
breakdowns
12
Maintenance Approaches
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 Maintenance - A combination of Time based and Predictive Maintenance and actions taken to sustain optimal equipment performance and preclude breakdowns.
= get around the problem
Solution = Work in batches
“We use the time it works to mass produce”
Today:
Objective = One piece flow Quality every time
Means = TPM
8
The Nine types of waste
9 Wastes
? Overproduction ? Delays (waiting time) ? Transportation ? Process ? 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
3
Total Productive Maintenance
Do these problems sound familiar?
? Equipment is always breaking down
? Operating machines at rated speeds creates defects
19
Division of Maintenance Duties between Production and Maintenance
Depending on knowledge and skills required,
responsibility for equipment maintenance tasks needs to be
* High safety risk tasks * Basic adjustments
20
Maintenance Task Allocation between Production and Maintenance
Volume of maintenance tasks
Maintenance Technicians
“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 detection of abnormalities ? Quick response
Typical success results after implementation of TPM: Breakdowns: 1/30 to 1/100 of prior level Machine defects: 1/30 to 1/40 of prior level Productivity: 30 - 100 percent increase
A STRATEGY FOR PERFORMANCE EXCELLENCE
1
Performance Excellence Series Training Module Elements
Executive Overview Lecture notes
Knowledge Breakthrough
Tools Workbook
Role in Lean Manufacturing…………………….8
Role of the Operator in TPM…………………..18
Autonomous Maintenance Implementation……22 Equipment Performance: Measurement & Management………………….56
13
Early Equipment Management
Optimizes equipment selection through:
? 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.
source: K. Shirose, TPM For Workshop Leaders, p. 10
7
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
5
Total Productive Maintenance
What it is:
1. Optimizes equipment efficiency 2. Implements a company wide Preventive Maintenance system 3. Involves production equipment designers, operators, and maintenance
Without TPM
Operation
MED & Industrial Engineering
The operator operates, maintenance maintains, etc.
Maintenance
With TPM
Operation
MED & Industrial Engineering
? MP Design: activity which is focused on minimizing future maintenance costs and production losses of equipment at the design stage.
14
Total Productive Maintenance
18
Total Productive Maintenance
TPM, the total approach ? The operator is the first line caretaker ? Maintenance personnel are the specialized caretakers.
Production Operators
defined:
Maintenance Technician Production Operator
* Equipment overhaul
* Basic lubrication
* Special skill tasks
* General cles * Multi-point inspection
Maintenance
Shared responsibilities
15
Equipment Maintenance Responsibilities
Autonomous maintenance
Operation
MED & Industrial Engineering
Maintenance prevention
? 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.
breakdowns
12
Maintenance Approaches
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 Maintenance - A combination of Time based and Predictive Maintenance and actions taken to sustain optimal equipment performance and preclude breakdowns.
= get around the problem
Solution = Work in batches
“We use the time it works to mass produce”
Today:
Objective = One piece flow Quality every time
Means = TPM
8
The Nine types of waste
9 Wastes
? Overproduction ? Delays (waiting time) ? Transportation ? Process ? 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
3
Total Productive Maintenance
Do these problems sound familiar?
? Equipment is always breaking down
? Operating machines at rated speeds creates defects
19
Division of Maintenance Duties between Production and Maintenance
Depending on knowledge and skills required,
responsibility for equipment maintenance tasks needs to be
* High safety risk tasks * Basic adjustments
20
Maintenance Task Allocation between Production and Maintenance
Volume of maintenance tasks
Maintenance Technicians
“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 detection of abnormalities ? Quick response
Typical success results after implementation of TPM: Breakdowns: 1/30 to 1/100 of prior level Machine defects: 1/30 to 1/40 of prior level Productivity: 30 - 100 percent increase