精益生产之全面生产维护 TPM(中英文版)

分析
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改进
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控制
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选定题目 列出客户 从顾客之声中列出关建需 求 定出项目焦点和重要指标 完成 PDF
绘制业务流程图 绘制价值流程图 制定数据收集计划 测量系统分析 收集数据 过程能力分析
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提出关键因子 区分关键因子 验证关键因子 评枯每个关键因子对结果 的影响 量化机会 根本原因排序 寻找根本原因针对关键因 子


A proactive system which monitors and corrects causes
An operations strategy based on understanding the cause and effect system affecting the major contributors to process performance
脑力风暴 拉系统 减少设置 TPM 流程图 标杆管理 亲和图 DOE 假设检验 力场分析图 树状图 甘特图
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查检表 运行图 柱状图 散布图 控制图 柏拉图 互动回顾 愚巧法
Revised 1-12-02
Total Productive Maintenance (TPM)
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Lean Six Sigma Improvement Process Road Map
Measure
Analyze Improve
全面生产维护 (TPM)
TPM
TPM 团队组织 设备综合利用率OEE
Control

TPM 活动步骤
Lean Six Sigma
RD011202
Measure
Analyze
Total Productive Maintenance (TPM)

TPM
TPM Team Organization Overall Equipment Effectiveness
Improve

Control

TPM Phases
Lean Six Sigma
RD011202
精益6 过程改善流程
定义
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Control
测量
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Critical X’s Confirmed Develop Potential Solutions Select Solution Optimize Solution Pilot Solution
Implement Process Changes and Controls Write Control Plan Calculate Final Financial/ Process Metrics Transition Project to Future Owners Identify Project Translation Opportunities
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过程图 价值分析 脑力风暴 投票归类法 柏拉图 因果图/鱼骨图 FMEA 查检表 运行图 控制图 量具 R&R
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Cp & Cpk 供应链加速器分析 多变动图i 盒状图 交互作用图 回归分析 ANOVA C&E 矩阵图 FMEA
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Total Productive Maintenance (TPM)
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Traditional Approach “Re-Active Maintenance”
Maintenance – “WE FIX” Perform all maintenance activities Perform “Fire Fighting” maintenance when a machine breakdown occurs Order and administer all tooling, supplies, etc. Perform Preventive Maintenance
TPM Definition

Control
A common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance.
Control
Manufacturing – “WE OPERATE” Generally does not perform any maintenance activities Contacts maintenance when a machine breakdown occurs Inactive during maintenance activities “Run it 'till it breaks”
Total Productive Maintenance (TPM)
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全面生产维护 (TPM)
定义:

Control
一种用于监控操作,设备保养,消除计划外停机,和提高作业与 保养协调程度的常识性方法。
Total Productive Maintenance (TPM)
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Total Productive Maintenance (TPM)
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Map Business Process Map Value Stream Develop Data Collection Plan Conduct Measurement System Analysis Collect Data Conduct Process Capability Analysis
Total Productive Maintenance (TPM)
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What’s in It for Me?

Control
Optimized process operations and maintenance
A method to replace the traditional approach of detecting and correcting faulty conditions as they occur
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Propose Critical X’s Prioritize Critical X’s Verify Critical X’s Estimate the Impact of Each X on Y Quantify the Opportunity Prioritize Root Causes Conduct Root Cause Analysis on Critical X’s
Define
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Control
Measure
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Analyze
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Improve
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Control
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Identify Problem Develop List of Customers Develop List of CTQ’s from Voice of the Customer Finalize Project Focus and Key Metrics Complete PDF

Implement maintenance audits
Total Productive Maintenance (TPM)
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个人学习意义

Control
流程作业和保养最优化
一种替代传统的在故障发生时检测并修复的方法; 一种源头监控和校正的先发系统; 一种基于对影响过程性能的主要因素其因果系统的理解工作 策略;
Cp & Cpk SupplyChainAccelerator Analysis Multi-Vari Box Plots Interaction Plots Regression ANOVA C&E Matrices FMEA
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Brainstorming Pull Systems Setup Reduction TPM Process Flow Benchmarking Affinity DOE Hypothesis Testing Force Field Tree Diagrams Gantt Charts
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课程目的

Control
学习一种方法以便:

将作业流程中的起作用的所有生产要素整合为一个单一 综合的衡量值（OEE）; 消除导致设备故障的因素; 使设备的养护清洁更易达成; 用预测性保养作为一种检测工具;


实施维护审查
Total Productive Maintenance (TPM)
Achieve zero equipment breakdowns and zero defects through prevention
Establish prevention by
Fra bibliotekMaintaining normal conditions
Early detection of abnormalities Quick response
Total Productive Maintenance (TPM)
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传统的反应式维护
维修部门–
“我们只管修理” 执行所有的维修作业 往往是一旦设备发生故障充 当救火员的角色; 负责定购和保管所有的工具, 备件等物资; 实施定期检修