一份老外的tpm讲义.ppt

source: K. Shirose, TPM For Workshop Leaders, p. 10
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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
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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
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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
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Maintenance Task Allocation between Production and Maintenance
Volume of maintenance tasks
Maintenance Technicians
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The Nine types of waste
9 Wastes
• Overproduction • Delays (waiting time) • Transportation • Process • Inventories • Motions • Defective products • Untapped resources • Misused resources
Division of Maintenance Duties between Production and Maintenance
Depending on knowledge and skills required, responsibility for equipment maintenance tasks needs to be defined:
department personnel 4. Involvement from Management down to floor workers 5. Implemented through small, self directed team activities
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Total Productive Maintenance
Expanding the Strategy through TPM
Introduction Role in Lean Manufacturing Role of the Operator in TPM Autonomous Maintenance Implementation Equipment Performance: Measurement and Management
Decrease of breakdowns
Decrease of inprocess adjustments
Optimization of operation speed
Manufacturing defects
Lead-time
Quality the first time
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Performance Excellence:
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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
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Total Productive Maintenance
Do these problems sound familiar? Equipment is always breaking down Operating machines at rated speeds creates defects Setups and adjustments take too long Minor machine stoppages are eroding productivity
Role in Lean Manufacturing…………………….8
Role of the Operator in TPM…………………..18
Autonomous Maintenance Implementation……22 Equipment Performance: Measurement & Management………………….56
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Total Productive Maintenance
TPM, the total approach The operator is the first line caretaker Maintenance personnel are the specialized caretakers.
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= 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
A STRATEGY FOR PERFORMANCE EXCELLENCE
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Performance Excellence Series Training Module Elements
Executive Overview Lecture notes
Knowledge Breakthrough
Tools Workbook
Maintenance Technician Production Operator
* Equipment overhaul
* Basic lubrication
* Special skill tasks
* General cleaning
* Complex adjustments
* Multi-point inspection
Production Operators
Autonomous maintenance implementation
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
Maintenance prevention
Maintenance
Breakdown maintenance Planned maintenance Predictive maintenance
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Total Productive Maintenance
TPM
Equipment in better working condition
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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. MP Design: activity which is focused on minimizing future maintenance costs and production losses of equipment at the design stage.
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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.
“We organize so it works continuously”
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Goals of TPM
Achieve zero equipment breakdowns and zero defects through prevention. Establish prevention by
Maintaining normal conditions Early detection of abnormalities Quick response