“我们所有人对我们的设备负责。”
5
Tip of the Iceberg 冰山的顶端
Failures 故障
Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw
materials,surface damage, cracking, overheating, vibration, noise, and other
abnormalities. 磨损、松驰、泄露、灰尘、污垢、腐蚀 变形、原材料粘黏、表面磨损、裂缝、 过热、震动、噪音及其它不正常现象。
Hidden Defects 隐藏的问题
6
Typical Causes of Machine Breakdown 典型的机械故障原因
Contamination of sensors, contacts and Connectors
Process Certification
Quality Clinic Activity
Mistake Proofing
1
全面生产性维护 ACE 生产部门合格水平
6S
全面性生产 维护
质量诊断程序 图表
减少生产 准备
市场反馈 分析
标准化 作业
根本原因 修正行动
程序验证
质量诊断 行动
防误措施
2
TPM 全面生产性维护
• Enhanced safety 提高安全性
– Find exposed wires, open belts, missing guards, loose hardware
– 发现暴露在外的电线、松开的安全带、缺少防护、 松开的部件
• Reduced waste 减少浪费
– Prevents loss of lubricant, compressed air – 防止润滑油、压缩空气的浪费
Failure 组件失灵
Dirt and dust on cooling fan 冷却风扇上有 灰尘和污垢
7
TPM Techniques TPM技术
• Simplify and Document TPM Activities. • 简化并记录TPM行动
• Use visual techniques to indicate
TPM’s focus is to prevent problems before equipment breaks. TPM 的焦点是要在设备出
故障以前防止问题出现。
4
Total Productive Maintenance
is a New Way of Working 全面生产性维护是一种全新的工作方式
what’s right / what’s wrong. • 运用直观技术来演示什么是
对的/什么是错的。
– PM Completed? 生产性维护完成了吗？ – Pressure gage 压力计 – Sight glass 视镜 – Arrows for motor rotation
and fluid circulation马达旋转和润油指示箭头 – markings for spare parts and fluids. – 备用零件和润滑油记号
Old Attitude:
过去的态度：
“I operate, you fix.” “我操作，你修理。”
“I fix, you design.” “我处理，你设计。”
“I design, you operate.” “我设计，你操作。”
TPM Attitude:
TPM态度：ຫໍສະໝຸດ “We are all responsible for our equipment.”
8
TPM Benefits TPM的益处
• Reduced maintenance costs
• 减少维护费用
– Breakdown maintenance is 10 times more costly than planned maintenance
– 故障维修费用是有计划进行维护费用的10倍以上
Total Productive Maintenance ACE Manufacturing Qualifying Level
TPM
6S
QCPC
Set-Up Reduction
Standard Work
Market Feedback Analysis
Root Cause / Corrective Action
Total Productive Maintenance is an equipment management strategy that improves equipment efficiency. 全面生产性维护是一种设备管理策略以提高设备效率。
Or, in other words... Treating the equipment like it is your own! 或者，换句话说……. 对待设备就象它是你自己的 一样！
3
TPM Key Concept TPM的重要概念
• Left neglected... Equipment Breaks Down • 如果不重视…设备很快就会坏
In the past, maintenance focused on fixing equipment after it broke. 过去，维护工作总是集中在设备坏了 以后对其进行修理。
Normal operating Range
正常操作范围
Danger!
危险！
Making PM devices more accessible. • 使生产性维护设备更容易获得
– Filters, fittings made more accessible 过滤器、各种装置 – Transparent panels to facilitate inspection 明了易读的仪表盘便于检查
传感器、触敏器、 连接器污染
Grit and chips
in revolving
or sliding parts 旋转或滑动零件 中的砂砾和碎片
I wonder what’s
going to fail next? 我在想下面还会出什么
问题呢？
Failure to
add oil. 没有加油
Component