全面生产维护TPM培训课件.pptx
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全面生产维护TPM培训课件.pptx
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全面生产维护(TPM),TPMTPM团队组织设备综合利用率OEETPM活动步骤,RD011202,TotalProductiveMaintenance(TPM),TPMTPMTeamOrganizationOverallEquipmentEffectivenessTPMPhases,RD011202,TotalProductiveMaintenance(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RACIQuad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ANOVAC&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,Revised1-12-02,TotalProductiveMaintenance(TPM),4,LeanSixSigmaImprovementProcessRoadMap,Analyze,Control,Improve,DefineIdentifyProblemDevelopListofCustomersDevelopListofCTQsfromVoiceoftheCustomerFinalizeProjectFocusandKeyMetricsCompletePDF,MeasureMapBusinessProcessMapValueStreamDevelopDataCollectionPlanConductMeasurementSystemAnalysisCollectDataConductProcessCapabilityAnalysis,AnalyzeProposeCriticalXsPrioritizeCriticalXsVerifyCriticalXsEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCauseAnalysisonCriticalXs,ImproveCriticalXsConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolution,ControlImplementProcessChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunities,Measure,Define,ProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadCharts,ProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&R,Cp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEA,BrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttCharts,CheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-Yoke,Revised1-12-02,TotalProductiveMaintenance(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,TotalProductiveMaintenance(TPM),6,LearningObjectives,Learnamethodto:
IntegrateoperationalproductivityfactorsapplicableinprocessindustriesinasinglecomprehensivemeasurementEliminatefactorscontributingtoequipmentfailureImproveaccessibilityforcleaningandmaintainingequipmentUsepredictivemaintenanceasadiagnostictoolImplementmaintenanceaudits,TotalProductiveMaintenance(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;,TotalProductiveMaintenance(TPM),8,WhatsinItforMe?
OptimizedprocessoperationsandmaintenanceAmethodtoreplacethetraditionalapproachofdetectingandcorrectingfaultyconditionsastheyoccurAproactivesystemwhichmonitorsandcorrectscausesAnoperationsstrategybasedonunderstandingthecauseandeffectsystemaffectingthemajorcontributorstoprocessperformance,TotalProductiveMaintenance(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。
TotalProductiveMaintenance(TPM),10,TotalProductiveMaintenance(TPM),TPMDefinitionAcommonsenseapproachtomonitoroperations,maintainequipment,eliminateunscheduleddowntime,andimprovethelevelofcooperationbetweenOperationsandMaintenance.,TotalProductiveMaintenance(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,TotalProductiveMaintenance(TPM),12,TPM,AchievezeroequipmentbreakdownsandzerodefectsthroughpreventionEstablishpreventionbyMaintainingnormalconditionsEarlydetectionofabnormalitiesQuickresponse,TotalProductiveMaintenance(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,TotalProductiveMaintenance(TPM),14,TraditionalApproach“Re-ActiveMaintenance”,Maintenance“WEFIX”PerformallmaintenanceactivitiesPerform“FireFighting”maintenancewhenamachinebreakdownoccursOrderandadministeralltooling,supplies,etc.PerformPreventiveMaintenance,Manufacturing“WEOPERATE”GenerallydoesnotperformanymaintenanceactivitiesContactsmaintenancewhenamachinebreakdownoccursInactiveduringmaintenanceactivities“Runittillitbreaks”,TotalProductiveMaintenance(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,TotalProductiveMaintenance(TPM),16,KeyDefinitions,PreventiveMaintenanceisatimeorusagebasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedondefinedtimeand/orusageintervalstopreventequipmentbreakdownsfromoccurring.PMSchedules,PredictiveMaintenanceisasituationbasedmethodofmaintainingequipment.Maintenanceactivitiesareperformedonequipmentbasedonvisiblesignalsordiagnostictechniquestopreventequipmentbreakdownsfromoccurring.VibrationAnalysisLaserMeasuringUltrasoundGeneratorTestingThermographyOilAnalysis,TotalProductiveMaintenance(TPM),17,现状分析和团队组织,评估当前的操作条件:
机器利用率,生产率等;维修费用(配件和人工)对实现TPM的各项工作进行优先次序评估潜在TPM倡导者及团队成员的实力挑选TPM倡导者及团队成员建立初始的实施专门小组确定团队目标,TotalProductiveMaintenance(TPM),18,PresentStateAnalysisandTeamOrganization,AssessCurrentOperatingConditionsMachineutilization,productivity,etc.Maintenancerepaircosts(partsandlabor)PrioritizeorderofTPMeffortsAssesscapabilitiesofpotentialTPMChampionsandTeamMembersSelectTPMChampionandTeamMembersEstablishinitialkick-offworkshopEstablishteamgoal,TotalProductiveMaintenance(TPM),19,典型的设备评价指标,利用率:
设备实际运转时间与总的可利用时间的比率;=实际运行时间/可运行时间效率:
实际产量与标准产量的比率=(实际产量/小时)/(标准产量/小时)产出:
用一特定时间段的产量来衡量=磅/小时,件数/小时,TotalProductiveMaintenance(TPM),20,TypicalOperationalProcessMeasurements,Utilization:
Theratioofequipmentactualoperatingtimetothetotalavailableoperatingtime=ActualOperatingTime/AvailableTimeEfficiency:
Theratioofactualproductproducedtoastandard=(ActualParts/Hour)/(StandardPart/Hour)Output:
Measureofoutputoveraspecifiedtimeperiod=lbs/hr,pieces/hr,TotalProductiveMaintenance(TPM),21,设备综合利用率OEE,设备综合利用率(OEE)是衡量一台设备按计划速度生产出合格产品的时间占全部时间的百分比.,TotalProductiveMaintenance(TPM),22,OverallEquipmentEffectiveness,OverallEquipmentEffectiveness(OEE)isthemeasureofthepercentoftimeapieceofequipmentisproducingqualityproductatthedesignedrate.,TotalProductiveMaintenance(TPM),23,OEE分解:
六大浪费,故障及轻微故障使设备中断运行的时间超过10分钟的故障或者中断时间少于10分钟的轻微故障.设置时间浪费任何与设备调整,装配,清洁相关的作业.,机器空转浪费设备在运转却没有用来生产产品所耗用的时间.速度浪费由于设备或产品的异常造成设备以低于标准速度或所设定的速度运转.,品质原因浪费为确保设备产出品的品质而采取相关的作业(过程中检查).返工浪费用于返修产品或生产出报废产品所耗用的时间.,TotalProductiveMaintenance(TPM),24,OEEBreakdown:
TheSixBigLosses,BreakdownsandMinorStoppagesMalfunctionscausingequipmenttostopprocessinggreaterthan10minutes(breakdowns)orlessthan10minutes(minorstoppages)SetupAnyactivityrelatedtoequipmentchangeover,setup,orcleaning.,IdlingTimeequipmentisrunningbutnotproducingproduct.SpeedLossesEquipmentoperatingatlessthanstandardordesignspeedduetoequipment/productabnormality,QualityFactorsActivitiesrelatedtoensuringthequalityoftheproductproducedontheequipment(in-processchecks).ReworkLossesThetimetakentore-processproductortimetaketoproduceun-usableproduct.,TotalProductiveMaintenance(TPM),25,六大浪费的识别练习,TotalProductiveMaintenance(TPM),26,SixBigLossesIdentificationExercise,TotalProductiveMaintenance(TPM),27,OEE的计算原理,承载时间(LT),设备运转总的可利用时间=40hrs,可用水平(AL),运行水平(OL),质量水平(QL),OEE,73%x91%x80%,26.3-3.1-2.1=80%26.3,28.9-1.5-1.1=91%28.9,质量原因,机器故障及轻微故障,行政事务/非作业时间,机器设置与调整,速度损失,机器空转,返工及报废,40-3.1-3.8-4.2=73%40,OEE=53%,ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrs,TotalProductiveMaintenance(TPM),28,CalculatingOEEElements,LoadingTime(LT),TotalHoursAvailableforEquipmentOperation=40hrs,AvailabilityLevel(AL),OperatingLevel(OL),QualityLevel(QL),OEE,73%x91%x80%,26.3-3.1-2.1=80%26.3,28.9-1.5-1.1=91%28.9,QualityFactors,BreakdownsMinorStops,andAdmin.,Setup,SpeedLosses,Idling,ReworkandScrap,40-3.1-3.8-4.2=73%40,OEE=53%,ALHRS=40-3.1-3.8-4.2=28.9hrsOLHRS=28.9-3.1-1.1=26.3hrsQLHRS=26.3-3.1-2.1=21.1hrs,TotalProductiveMaintenance(TPM),29,世界级的OEE性能水平,承载时间(LT),同步计划运转时间及生产性防护时间,可用水平(AL),运行水平(OL),质量水平(QL),OEE,90%x95%x99%,质量原因,机器故障及轻微故障,行政事务/非作业时间,机器设置与调整,速度损失,机器空转,返工及报废,OEE=85%是世界级的性能水平,AL始终保持在90%以上,OL维持在95%以上,QL不低于99%,TotalProductiveMaintenance(TPM),30,WorldClassOEEPerformance,LoadingTime(LT),OperationTimeandPMTimeisscheduledsynchronizingthetwo,AvailabilityLevel(AL),OperatingLevel(OL),QualityLevel(QL),OEE,90%x95%x99%,QualityFactors,BreakdownsMinorStops,andAdmin.,Setup,SpeedLosses,Idling,ReworkandScrap,OEE=85%isWorldClassPerformance,TheALisconsistentlykeptatorabove90%,TheOLismaintainedatorabove95%,TheQLisatorabove99%,TotalProductiveMaintenance(TPM),31,使设备恢复到可靠状态,消除故障,开发PM维护保养资料库,消除缺陷,阶段I,阶段II,阶段III,阶段IV,TPM阶段,TotalProductiveMaintenance(TPM),32,ReturnEquipmenttoReliableCondition,EliminateBreakdowns,DevelopPMInformationDatabase,EliminateDefects,PHASEI,PHASEII,PHASEIII,PHASEIV,TPMPhases,TotalProductiveMaintenance(TPM),33,六大团队活动,1.通过小规模的小组活动来提高机器的正常运行时间,消除造成停工的主要根源:
机器的启动损失机器的故障损失待料损失和生产安排不当带来的停机损失2.使操作员熟练地参与如润滑,清洁,故障检验等基本的保养维护.,TotalProductiveMaintenance(TPM),34,SixTeamActivities,1.Usesmallgroupactivitiestoimprovemachineuptimebyeliminatingthemajorsourcesofdowntime.StartupLossesBreakdownLossesMaterialandSchedulingLosses2.Involvethemachineoperatorsaswellasskilledtradesinbasicpreventativemaintenancesuchaslubrication,cleaning,andinspectionfordefects.,TotalProductiveMaintenance(TPM),3
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