Towards Operational Excellence
LEAN Practitioner Program
Total Productive Maintenance 全面生產性維護
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Lean Tools 精益工具
Lean Overview 精益概述 Change M & Waste E 改變觀念&消除浪費 Performance Metrics 績效指標 Value Stream Mapping 价值流程圖 Visual Management 目視管理 Error Proofing 防錯法 SMED / Quick Changeover 快速切換 TPM 全面生產性維護 Layout Optimization/Cell 布局優化／Cell Material Control 物料控制 Theory Of Constraints 瓶頸理論 Lean Diagnostic 精益診斷
作員”到“設備是我職責的一部分”
Equipment problems are opportunities for improvement
設備的問題也就是改善的机會
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Training 培訓
To develop a knowledgeable operator 培養有見識的員工
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Introduction 介紹
1980s TOTAL PRODUCTIVE MAINTENANCE
全面生產性維護
“Productive Maintenance with Total Employee Participation”
“全面維護,全員參与”
1970s PRODUCTIVE MAINTENANCE
加強團隊合作和相互關系
Value of Autonomous Maintenance 自主維護的价值 Change of work culture from “I can only operate this machine” to
“machine is a part of my duty” 改變工作文化,從“我是這台設備的操
•Cost 成本
More Effective Use of Manpower Reduced Maintenance Costs Reduced Energy Costs
•Quality 品質
Reduced Defects in Process Reduced Customer Claims
•Morale 士气
Improve Quality 改善品質 Reduced Cycle Time 降低周期時間 Reduce Speed Loss 降低速度損耗 Reduce Equipment Maintenance Cost 降低設備維修成本 Improve team work and cross functional relationship
There are many tools and techniques in the Lean „tool box‟, all suited to different applications and circumstances. 在LEAN工具箱中有許多工具和技巧,它們可以用于各種不同的情況.MAINTENANCE Breakdown 事后維護 “停机維修”
The importance of excellent „asset stewardship‟ is now recognized by the world‟s leading manufacturing companies as a critical success factor. 卓越的固定資產管理目前已被世界領先的制造公司作為一個關鍵的成功因素
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How to achieve Autonomous Maintenance 如何達到自主維護
5S Management 5S管理
Visual Management 目視管理
Standardized Work 標准化作業 Equipment operation skill enhancement
所有毛病和故障都須維修員來處理
It's your problem!!
All equipment have faults and failures
New attitude 新的態度 We share responsibility for caring of our machine, as if they are extensions of our limbs and arms
這些簡單的問題怎樣預防?
To make manufacturing an active partner with process engineering and maintenance for improving overall performance of machines
將生產部變成PE和ME的積极伙伴來改善機器的總效能
我們要分擔責任來看護機器﹐把機器當作我們的四肢
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Benefits of Atuonomous Maintenance 自主維護的好處
Benefits of Autonomous Maintenance include 自主維護的好處
Improve Productivity 提高生產力
清洁和檢查不是員工的責任
all equipment will eventually give faults and failure
所有設備終究會有毛病和故障
all faults and failures of equipment can be rectified by maintenance
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什么是全面生產性維護(TPM)?
Total Productive Maintenance or TPM in short is a concept of optimizing equipment effectiveness through total employee involvement 全面生產性維護(簡稱TPM)是通過全員參与來改善 机器一生的總性能. TPM aims to reduce statistical variability on equipment by improving the equipment performance in order to achieve a more robust and predictable process TPM目的在于改善机器的 績效,降低机器的統計波動, 來達到更可靠的工序.
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Training Objectives 培訓目的
After completion of this training you should be able to 完成此課程后妳應該能夠:
Understand what TPM is 理解TPM是什么
Have an overview of Autonomous Maintenance activities 有自主維護的概念 Understand Equipment Losses 理解設備損失 Able to focus on equipment improvement using OEE 能用OEE來關注設備的改善
提高設備操作技術
Break down barriers 打破障礙 High level maintenance management 高水平維護管理
Ownership responsibility 主人翁精神 Transfer of PM activities to operator 員工參与技術性的維護活動 All employees involved 全員參与
部門相當于同一輛車上的輪子
Operator 操作員
Maintenance 維修員
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Change Attitude 態度改變
Dramatic change in attitude 在態度上的戲劇性變化 Old attitude 老的態度 it is no the operator„s responsibility to perform cleaning and inspection
生產性維護
“Recognition of Equipment Maintenance Issues at Plant Design Stage”
“在設計階段強調設備維護”
1960s PREVENTATIVE MAINTENANCE
預防維護 “I operate...you fix””我操作...你維修”
Production, maintenance & engineering crew support each other and understand how their roles interact in order to work towards Zero Breakdown, Zero Accident, Zero Defects 生產﹑維修和工程的同事互相支持﹐理解相互的職責﹐共同達 到零故障﹑零事故﹑零不良﹒
How equipment functions? 設備怎么運作? What common problem occurs? 什么樣的常見問題發生?
How to detect problems through five senses/feeling?
怎樣通過五官/感覺來發現問題?
That there is something „FUNNY‟? 有趣嗎? why and how those simple problems can be prevented?