全面生产维护 (TPM),TPM TPM 团队组织 设备综合利用率OEE TPM 活动步骤,RD011202,Total Productive Maintenance (TPM),TPM TPM Team Organization Overall Equipment Effectiveness TPM Phases,RD011202,Total Productive Maintenance (TPM),3,精益6 过程改善流程,分析,控制,改进,定义 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,测量 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,分析 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,改进 关键因子确认 发掘潜在的解决方法 选择方案 优化方案 实行方案,控制 过程变革和控制 制定控制计划 计算最终财务 过程指标 项目过渡给未来项目管理者 项目鉴 别 转化机会,测量,定义,项目编号工具 项目定义表 净现值分析 内部回报率分析 折算现金流分析 PIP管理过程 RACI Quad 表,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,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,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,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),4,Lean Six Sigma Improvement Process Road Map,Analyze,Control,Improve,Define Identify Problem Develop List of Customers Develop List of CTQs from Voice of the Customer Finalize Project Focus and Key Metrics Complete PDF,Measure Map Business Process Map Value Stream Develop Data Collection Plan Conduct Measurement System Analysis Collect Data Conduct Process Capability Analysis,Analyze Propose Critical Xs Prioritize Critical Xs Verify Critical Xs Estimate the Impact of Each X on Y Quantify the Opportunity Prioritize Root Causes Conduct Root Cause Analysis on Critical Xs,Improve Critical Xs Confirmed Develop Potential Solutions Select Solution Optimize Solution Pilot Solution,Control Implement Process Changes and Controls Write Control Plan Calculate Final Financial/ Process Metrics Transition Project to Future Owners Identify Project Translation Opportunities,Measure,Define,Project ID Tools Project Definition Form Net Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management Process RACI Quad Charts,Process Mapping Value Analysis Brainstorming Multi-Voting Techniques Pareto Charts C&E/Fishbone Diagrams FMEA Check Sheets Run Charts Control Charts Gage R&R,Cp & Cpk SupplyChainAccelerator Analysis Multi-Vari Box Plots Interaction Plots Regression ANOVA C&E Matrices FMEA,Brainstorming Pull Systems Setup Reduction TPM Process Flow Benchmarking Affinity DOE Hypothesis Testing Force Field Tree Diagrams Gantt Charts,Check Sheets Run Charts Histograms Scatter Diagrams Control Charts Pareto Charts Interactive Reviews Poka-Yoke,Revised 1-12-02,Total Productive Maintenance (TPM),5,课程目的,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),6,Learning Objectives,Learn a method to: Integrate operational productivity factors applicable in process industries in a single comprehensive measurement Eliminate factors contributing to equipment failure Improve accessibility for cleaning and maintaining equipment Use predictive maintenance as a diagnostic tool Implement maintenance audits,Total Productive Maintenance (TPM),7,个人学习意义,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;,Total Productive Maintenance (TPM),8,Whats in It for Me?,Optimized process operations and maintenance A method to replace the traditional approach of detecting and correcting faulty conditions as they occur 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,Total Productive Maintenance (TPM),9,全面生产维护 (TPM),定义: 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),10,Total Productive Maintenance (TPM),TPM Definition A common sense approach to monitor operations, maintain equipment, eliminate unscheduled downtime, and improve the level of cooperation between Operations and Maintenance.,Total Productive Maintenance (TPM),11,TPM,通过实施预防实现设备零故障和零缺陷; 预防工作将立足于以下方面: 维持正常的生产条件 及早发现异常 快速反应,Total Productive Maintenance (TPM),12,TPM,Achieve zero equipment breakdowns and zero defects through prevention Establish prevention by Maintaining normal conditions Early detection of abnormalities Quick response,Total Productive Maintenance (TPM),13,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,生产部门 ”我们只管使用“ 通常不作任何维护活动 一旦设备出现故障就与维修部门联系 维修作业中只能停工; 一直用到坏了为止,Total Productive Maintenance (TPM),14,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,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),15,主要概念,定期保养是一种基于时间长短或使用状况对设备进行检修的方法.在指定时间或在使用空档间对设备实施检修作业以防止设备发生故障. 定期保养计划,预测性保养是一种基于设备状态的维护方法.根据可视信号或检测技术的情况来实施保养以防止设备发生故障. 振动分析 激光探测 超声波检测 发电机测试 热感应 油况分析,Total Productive Maintenance (T