Preventative Maintenance
TMP培训资料
- 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
与TPM有关的两大管理系统
• 5S系统 • 视觉化管理系统 (VCS) • 5S和VCS系统是开展TPM活动的基础
开展TPM的三大工具
• One Point Lesson 一点课 基础知识(常识) / 出现的问题 / 改进改善个案
• Activity Board 活动板 以视觉冲击的形式,在工作现场展示我们需要的所有信息
• Total Product Management 产品全面管理
• Total Profit Management 全员效益管理
• Total Plant Management 全员车间管理
• Tapping People‘s Minds 开发人的思维
• Teams Produce More 更多的产出
• Predictive Maintenance 预测维护 (PM)
• Plant Maintenance / Process Maintenance 生产制造维护 (PM)
TPM的发展历史
• Preventative Maintenance 预防性维修 • Corrective Maintenance 纠正性维护 • Maintenance Prevention 维修的预防 • 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)
充电站巡查巡检计划表
充电站巡查巡检计划表英文回答：Electric Vehicle (EV) Charging Station Inspection and Maintenance Plan.Objective:To ensure the safe, reliable, and efficient operation of electric vehicle (EV) charging stations.To identify and address potential hazards and issues before they become major problems.To maintain compliance with all applicable regulations and industry standards.Scope:This plan applies to all EV charging stations ownedand operated by [Organization Name].The plan includes both routine inspections and preventative maintenance tasks.Frequency and Duration:Routine inspections: Daily, weekly, monthly, and annually.Preventative maintenance: Quarterly, semi-annually, annually.Inspection and Maintenance Tasks:Daily:Visual inspection of the charging station for any damage or debris.Check for loose connections or exposed wires.Verify that the charging station is operational and providing power to vehicles.Weekly:Clean the charging station and remove any debris.Test the functionality of the charging station using a test vehicle.Record any issues or observations in the inspection log.Monthly:Perform a comprehensive inspection of the charging station, including all electrical components.Check the charging station's software for updates.Clean and lubricate all moving parts.Annually:Conduct a thorough inspection of the charging station, including all electrical components and software.Test the charging station's functionality under various load conditions.Calibrate the charging station's meter to ensure accurate billing.Quarterly:Inspect the charging station's electrical panel and wiring.Check the battery backup system for proper operation.Clean and inspect the charging station's connectors.Semi-Annually:Inspect the charging station's grounding system.Check the charging station's cooling system for proper operation.Tighten all electrical connections.Annually:Perform a comprehensive inspection of the charging station, including all electrical components, software, and hardware.Test the charging station's functionality under various load conditions.Calibrate the charging station's meter to ensure accurate billing.Reporting and Documentation:All inspections and maintenance tasks must be documented in the inspection log.The inspection log must be reviewed and signed by the responsible technician.Any issues or concerns must be reported to the supervisor immediately.Training and Qualifications:All personnel responsible for inspecting and maintaining EV charging stations must be trained and qualified.Training must include topics such as electrical safety, charging station operation, and preventative maintenance.Safety:All inspections and maintenance tasks must be performed in accordance with all applicable safety regulations.Personnel must wear appropriate personal protective equipment (PPE) when working on EV charging stations.中文回答：电动汽车 (EV) 充电站巡查巡检计划。
设备维护保养计划
设备维护保养计划⏹维修计划⏹什么是维修计划?⏹维修种类⏹设备,设施预防性维修⏹公共区域预防性维修⏹客房区域预防性维修⏹What is Planned Maintenance⏹PLANNED 计划⏹Activity for which a pre-determined job procedure has beendocumented.⏹All labor, materials, tools, and equipment required to carryout the task have been estimated.⏹Their availability assured before commencement of the task.⏹MAINTENANCE 维修⏹is to KEEP in its existing state⏹to PRESERVE⏹CONTINUE in good operating condition⏹PROTECT current condition⏹Maintenance Types1. Reactive maintenance (Break down maintenance)2. Preventative maintenance (Elective maintenance)预防性维修•Periodic maintenance 定期维修•Predictive maintenance (PdM) 预测性维修3. Corrective maintenance 改进性维修4. Maintenance Prevention 维修预防5. Total Productive Maintenance (TPM) 大修⏹ 1. Reactive maintenance⏹It means waiting till equipment fails and repairing it.⏹Such a thing could be used when the equipment failure does not significantlyaffect the operation or service standards.⏹Could generate significant loss in revenue and higher repair cost.⏹Most importantly would negatively impact customer satisfaction.Not Recommended⏹ 2. Preventive maintenance⏹Is a maintenance program designed to⏹retain the healthy condition of equipment and extendequipment life⏹prevent deterioration⏹prevent failure and improve reliability⏹Improve equipment availability⏹Is achieved through either inspection of equipment conditionor diagnosis of equipment condition, to measure deterioration.⏹It is further divided into⏹Periodic maintenance⏹Predictive maintenance.⏹Just like human life is extended by preventive medicine, theequipment service life can be prolonged by doing preventivemaintenance.⏹2a. Periodic maintenance⏹Periodic maintenance consists of periodically inspecting, servicing andcleaning equipment and replacing parts to prevent sudden failure and process problems.⏹This method is also called Time based maintenance - TBM⏹预测性维修⏹Is techniques that help determine the condition of in-serviceequipment in order to predict when maintenance should beperformed⏹Compared to periodic maintenance, predictive maintenance iscondition based maintenance⏹Enables to determine the remaining service life based on diagnosisand analysis.⏹Allows the use of parts to the limit of their service life resulting incost savings.⏹This approach offers cost savings over Periodic (time-based)maintenance because tasks are performed only when needed.⏹ 3. Corrective maintenance⏹ 4. Maintenance prevention⏹生命安全檢查清單⏹保障客人和員工的安全。
EUGMP附录1无菌产品生产-2020版（中英文对照）
EUGMP附录1无菌产品生产-2020版（中英文对照）Annex 1 : Manufacture of Sterile ProductsEU GMP 附录1 无菌产品生产-2020版1 Scope范围The manufacture of sterile products covers a wide range of sterile product types (active substance, sterile excipient, primary packaging material and finished dosage form), packed sizes (single unit to multiple units), processes (from highly automated systems to manual processes) and technologies (e.g. biotechnology, classical small molecule manufacturing and closed systems). This Annex provides general guidance that should be used for the manufacture of all sterile products using the principles of Quality Risk Management (QRM), to ensure that microbial, particulate and pyrogen contamination is prevented in the final product.无菌产品的生产涵盖了广泛的无菌药品类型（活性成分，无菌辅料，内包材和制剂），包装量（从单个单位到多个单位），工艺（从高度自动化系统到人工操作）和技术（例如生物技术，常规小分子生产以及密闭系统）。
酒店工程部维保计划
酒店工程部维保计划英文回答：Hotel Engineering Maintenance Plan.Background:Hotels are complex facilities that require a high level of maintenance to ensure the comfort and safety of guests.A well-developed engineering maintenance plan is essential for managing the upkeep of these facilities.Objectives:Ensure the smooth and efficient operation of all hotel systems and equipment.Minimize downtime and disruption to hotel operations.Extend the lifespan of hotel assets.Reduce operating costs through proactive maintenance.Enhance guest satisfaction and safety.Key Components of a Hotel Engineering Maintenance Plan:1. Preventive Maintenance: Regularly scheduled inspections and maintenance tasks designed to prevent equipment failures and identify potential issues early on.2. Predictive Maintenance: Using sensors and monitoring systems to detect potential problems before they occur, enabling proactive maintenance interventions.3. Corrective Maintenance: Addressing equipmentfailures or breakdowns promptly to restore functionality and minimize downtime.4. Emergency Maintenance: Responding to urgent maintenance issues that require immediate attention to ensure guest safety or prevent major damage.5. Inventory Management: Maintaining an accurate inventory of spare parts and supplies to ensure prompt and efficient repairs.6. Work Order Management: Tracking maintenance requests, scheduling work, and ensuring timely completion.7. Performance Monitoring: Regularly reviewing maintenance performance to identify areas for improvement and optimize efficiency.8. Training and Development: Providing ongoing training to maintenance staff to keep them up to date on best practices and emerging technologies.Implementation:To implement an effective hotel engineering maintenance plan, it is crucial to:Establish clear roles and responsibilities formaintenance staff.Set up a structured maintenance schedule based on equipment manufacturer recommendations and hotel usage patterns.Utilize technology to streamline work order management and performance monitoring.Conduct regular inspections and audits to ensure compliance and identify areas for improvement.Foster a culture of preventative maintenance to minimize downtime and expenses.Benefits of a Hotel Engineering Maintenance Plan:Improved guest satisfaction through a comfortable and well-maintained environment.Reduced operational costs by preventing costly repairs and extending equipment lifespan.Enhanced safety through proactive maintenance and prompt response to emergencies.Streamlined maintenance operations through efficient work order management and inventory control.Increased efficiency and productivity of maintenance staff.中文回答：酒店工程部维保计划。
博格特PICP维护建议说明书
Borgert PICP Maintenance Recommendations:MANUFACTURER OF PREMIUM C ONCRETE PAVING STONES, SL ABS & WALLSOVERVIEW:PREVENTATIVE MAINTENANCE:CONSIDERATIONS:B orgert’s Permeable Interlocking Concrete Pavement (PICP) System is a stormwater management technique to prevent harmful runoff fromentering waterways. The system is considered 100% permeable and can be designed to capture a certain design storm’s precipitation and infiltrate the water back into the ground or exfiltrate out through a pipe. The system traps a high amount of pollutants and debris in the joints, preventing it from entering waterways or drinking water supplies. This does lead to the need to maintain the system. This document provides an overview of maintenance techniques and guidelines depending on the type of project.Tolerance: A conservative initial infiltration rate of the system is 300 inches/hour. Slight clogging of the sys-tem can still allow infiltration rates to accommodate the design storm.Lack of maintenance will cause the system to clog, defeating the purpose of using permeable pavement. Clogging will also cause deterioration of the paver as it will sit in a constant state of saturation.Joint Material: Keep the joints filled with the proper material, check and refill every 6 months. The fill should reach the top of the chamfer.Contributing Areas: If there is a high ratio of run-on to surface area of the system, greaterand more frequent maintenance will be required.Proper Installation: Use techniques and materials according to Borgert’s specifications; keep the site clean and unclogged during installation.Slope: If the system itself is sloped, the area must be large enough to capture the design storm on the system without running off. Current estimates from research indicate a slope less than 10% will not impact the infiltration rate.Surrounding Vegetation and Planting: Ensure that the adjacent landscaping is strong, prevents erosion of soils onto the pavers, and does not contribute to clogging from falling leaves or fruits. Promptly remove grass clippings.Ice: If the goal is to eliminate the formation of ice, the snow needs to be removedpromptly and the systems must remain unclogged.Awareness: Ensure anyone working near the site is aware of the system and does not place landscaping materials on the system or close enough to cause future runoff and no snow is piled throughout the winter. Do not allow sanding during the winter. R E G E N E R A T IV E A IR V A C U U M T R U C K C L O G G E D W E L L -M A IN T A IN E D R E F IL L IN G J O IN T M A T E R IA LWINTER MAINTENANCE:EVIDENCE OF CLOGGING:TOOLS:MAINTENANCE PLAN:Snow Removal: Shovel or plow as immediately as possible following a snowfall. Do not pile on permeable rge Scale:• Regenerative Air Vacuum: Will remove the top ½” of debris and joint material, new joint material must be swept back into the joints. This is a restorative technique that will return the system to near its initial infiltration capacity. • Street Sweeper: Will remove loose debris on the pavers or on the top layer of the joints. This will not remove embedded debris and should be performed more frequently to avoid the need for more restorative tactics.• Inspect the area directly following a rain event to checkfor standing water (after a major event & at least 3 times a year)• Use small-scale techniques to address small areas of clogging• Maintain the correct level of joint material• General preventative maintenance to reduce the need for majorrestorative techniques• Regenerative Air Vacuum: when major clogging occurs.Recommended 1-2 times a year for commercial applications andonce every 1-5 years for residential applications, vacuumingfrequency depends on usage.Small Scale:• Shop vacuum • Small scale street vacuum Preventative:• Leaf blower • Hard bristle broom• Standing water during or directly following a minor storm event• Visible debris in the joints• Water running off or pooling in large areas• Weed growthSalt/Deicing Chemicals: Do not use sand. The best option is to use the joint material for grit.Salt: When the system is clean and snow is removed promptly, far less salt/deicingchemicals should be used. Use proper judgement to gauge the amount of ice. Therewill most likely be little ice accumulation on the surface.MAIN OFFICE:WESTERN OPERATIONS: 5170 Kalamath Street | Denver, CO 80221 | 303.783.3864MADISON, WI: 6402 Loftus Road | Madison, WI 53532 | 800.622.4952DESIGN SHOWROOM:W W W.BORGER TPRODUC S T A N D IN G W A T E R。
Atlas Copco 复杂手动装配过程错误防止方法说明书
SOLUTIONAtlas Copco worked with the customer’s Production Engineering and Quality Engineeringdepartments to determine that the lack of operator instructions was the main weakness of thecurrent assembly process. We worked together to develop a fully integrated error-proofingsolution that included operator guidance software, complete with build sequence instructionsand all supporting accessories (i.e. barcode scanner, socket trays, printer, etc.) to improveoverall throughput and traceability of the process. This fully integrated error-proofing solutionalso minimized the labor-intensive rework that was ultimately costing the customer hundredsof thousands of dollars.IMPACTWith this solution we were able to reduce quality issues that caused the labor-intensive rework and limited the production throughput. The customer said, “We would not have been able to maintain the business with customers for the past couple of years had the AC operator error proofing solution not been purchased.” The customer now has complete traceability, which offers intangible value in establishing production processes that will ensure long-term sustainability.$250,000ANNUAL SAVINGS ANNUAL REWORK COST: $50,000 USD THROUGHPUT INEFFICIENCIES:$20,000 USDPAYBACK IN MONTHS:19.5 MONTHS TOTAL ANNUAL SAVINGS: $250,000 USD$300,000 ANNUAL SAVINGSProduction uptime at our customer’s facility was adversely affected whentheypracticesdowntime. The customer was averaging 10 minutes of downtime per monthat a rate of $2,500 per minute, or approximately $300,000 per year, due todowntime caused by tool failures.SOLUTIONAfter a deep dive into the customer assembly processes and maintenance practices, it wasproven that the run-to-failure model was the root cause of the tool failures and, ultimately, thehigh costs associated with them. Through our Service group at Atlas Copco, we were ableto implement a full preventative maintenance program on all tools. It included software thatnotifies the engineers when the tool had reached the cycle count at which it needs preventativemaintenance done.IMPACTImplementing a preventative maintenance program with the Visual Manager software allows the production engineer or maintenance staff to pull the tool offline prior to failure, which reduces unplanned downtime. In fact, the customer said, “90% of unexpected tool failure has been eliminated from our plant with the help of the PM program and Visual Manager.”PAYBACK IN MONTHS:6 MONTHSTOTAL ANNUAL SAVINGS:$300,000 USDMINUTES OF DOWNTIMEPER MONTH: 10 MINUTESCOST PER MINUTE OFDOWNTIME: $2,500 USDSOLUTIONAfter observing the current process and component stack up, Atlas Copco determined withthe customer that we should implement an electric tool with advanced fastening strategyto overcome the prevailing torque issues. Additionally, to prove that an advanced fasteningstrategy would detect the current failure mode, as well as other potential fastening failures, astudy was done with the Production Optimization group at Atlas Copco. Through that study, afastening program utilizing “PVT Selftap” strategy was developed and implemented on a newelectric tool system.IMPACT“Since the installation of all tooling and Production Optimization implementation, we have not incurred any additional containment cost.” - Customer$60,000ANNUAL SAVINGSCONTAINMENT COST PERINSTANCE: $30,000 USDINSTANCES PER YEAR:2 INSTANCESANNUAL CONTAINMENTCOST: $60,000 USDTOTAL ANNUAL SAVINGS:$60,000 USDPAYBACK IN MONTHS:9 MONTHSSOLUTIONThrough testing, we were able to show the impact of “over-torqueing” an M8 bolt/hard joint withthe click wrench by an added 10 degrees, plus increased torque by 10 Nm or 40%, which in turnput the joint out of specification. We also demonstrated the capabilities of the Atlas Copco SWR(Slipping Wrench) mechanical wrench that utilizes a cam-over mechanism to make overloadingthe wrench impossible. Through this demonstration, the customer agreed to switch all standardclick wrenches over to the Atlas Copco SWR model. IMPACTWith the high process capability delivered by the cam-over mechanism, over-tightening is eliminated. The customer is no longer stripping threads on the castings, thereby eliminating scrap costs associated with “over-torqueing”.$9,659ANNUAL SAVINGS COST PER SCRAPPED PART: $74.30 USD PAYBACK IN WEEKS:1.5 WEEKS TOTAL ANNUAL SAVINGS: $9,659 USD10 PARTS SCRAPPED PER MONTH: $802 USD。
10 ICP-MS Preventative Maintenance
Preventative Maintenance
– Estimated time to complete the PM is 8 hours – Many of the items inspected and replaced during the preventative maintenance visit are considered by Varian to be consumable items. Unless these items are covered by a maintenance contract or agreement, they will be replaced at the customer's expense
Preventative Maintenance
– After completing the PM both the customer and the CSR should sign the maintenance checklist. – Place the a copy of the completed checklist and all printouts in the instrument log book. – Note that the log book must be provided by the customer as it is not shipped with the instrument. All data kept in the log book will provide a valuable reference for future preventative maintenance and troubleshooting activities.
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TO:Equipment UserSUBJECT:Preventative Maintenance for the microwave powered UV system.A general PM schedule for your UV system is detailed below:Power supply:There are no regular maintenance procedures that apply to the power supply except to verifyproper operation of the front cooling fan(s) and to replace filters, if so equipped. Mechanical placement of power supplies should always allow for the unrestricted air movement at front andrear of the power supply chassis. Since dirt and/or dust deposits can settle on internal electrical components during use, it is advised that this material be removed with a source of drycompressed air during normal scheduled down time.Irradiator:(Regular maintenance) * Every 30 days of operation or as needed* NOTE: Dirty operating environments may require more frequent service.1)Remove irradiator from it’s light-shield, and carefully place on workbench with the lampcavity facing up.2)Remove the RF screen assembly, which covers the lamp cavity, and inspect fine tungstenmesh for any signs of damage. Damage includes tears or punctures in screen mesh, especiallywhere the screen material is attached to screen frame, arcing on the braided gasket material under screen frame, loose or missing parts. Replace screen assembly if there are any signs of damage.3)Remove UV bulb, and clean with “Windex” glass cleaner and a lint- free cloth. Alcohol ( IPA ) can also be used to clean the UV bulbs and reflector.During normal use, foreign material that has passed through the irradiator air supply filters willdeposit on the outer surface of the UV bulb and reflector.IMPORTANT: These external deposits are difficult to remove, and can eventuallycontribute to a reduction of UV energy at the irradiator focal point.4)Inspect the elliptical reflector for signs of RF damage. This may be seen as a pitting of thereflective surfaces, dark discoloration on front face, top edges, or at end reflectors. Replace entire reflector assembly if any damage is observed. Note condition of polished surfaces, as a dull orhazy reflector finish can severely effect the performance of this equipment. Due to the heat inand around this lamp cavity, most chemicals that come in contact with reflectors/bulbs will bedifficult to completely remove once the irradiator has been in operation for some time.Clean reflectors with “Windex” glass cleaner or alcohol (IPA) and a lint-free cloth.Retighten all reflector screws. Normal irradiator operation may cause these screws to loosen, contributing to RF arcing or pitting on the rear surface of the aluminum reflector and wave-guides.At time of reflector removal or replacement, do inspect the ignitor bulb for signs of damage, including loose quartz envelope, broken wire antennae, or improper installation. If damage exists, replace ignitor bulb, and mounting clip if necessary.Clean ignitor bulb with alcohol and a lint-free cloth.5)Reinstall UV bulb into lamp cavity, being careful not to touch quartz surface.If quartz bulb surface is touched, clean with “Windex” glass cleaner and a lint free cloth. Use a glass cleaner that is free of waxes, silicone, and polishes.NOTE: The use of alcohol as a cleaning agent may not completely remove grease and oils from the outer surface of the bulbs and reflectors.Operation of UV bulb with external deposits may cause premature failure of the quartz.6)Reinstall the RF screen over irradiator lamp cavity, and fasten with screws provided.Hand-tighten all screws. Do not over-tighten these screws as damage to the screw heads will result, making later removal of RF screen very difficult.NOTE: Do not operate this equipment with missing or damaged hardware.7)Reinstall UV irradiator into light-shield, being careful not to damage the RF screen mesh.8)Reconnect the high voltage cables at the irradiator. Verify a complete connection. IMPORTANT: Verify that all cable connectors are in good condition, and there are no damaged/missing parts. Damage to HV connectors or the wire insulation will require complete cable replacement. Never attempt to repair HV cables.9)Change air supply filters on a regular schedule to prevent the buildup of foreign material on bulb, reflector, and magnetron assemblies. Airborne impurities can degrade the optical performance of both the UV bulb and the polished reflector surfaces.10)Verify irradiator inlet cooling air to be within the proper specification. Operation of irradiator below the minimum air cooling specification can result in premature failure of major components. Severe damage to magnetrons and quartz bulb will result.Consult Fusion OPERATION / MAINTENANCE manual for specific instructions on how to correctly measure irradiator air pressure values.11)Verify that RF detector is in good condition, and there are no damaged parts.Test the operation of RF detector. Place system in “STANDBY” or “LAMP-ON”, thenpush the black button on the side of RF-1 detector for approx. 4 seconds. At this time the power supply should fault out with an indication of; RF INTLK。