TPM全面生产维护课件.ppt
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1、2022/12/6,TPM全面生产维护,TPM全面生产维护,TPM全面生产维护,Total Productive Maintenance (TPM),TPMTPM Team OrganizationOverall Equipment Effectiveness TPM Phases,RD011202,TPM全面生产维护,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
2、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
3、散布图控制图柏拉图互动回顾愚巧法,Revised 1-12-02,TPM全面生产维护,Lean Six Sigma Improvement Process Road Map,Analyze,Control,Improve,DefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDF,MeasureMap Business ProcessMap Value StreamD
4、evelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability Analysis,AnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical Xs,Imp
5、roveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot Solution,ControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation Opportunities,Measure,Define,Pro
6、ject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad Charts,Process MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl Cha
7、rtsGage R&R,Cp & CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEA,BrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt Charts,Check SheetsRun ChartsHistogramsScatter Diagram
8、sControl ChartsPareto ChartsInteractive ReviewsPoka-Yoke,Revised 1-12-02,TPM全面生产维护,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,TPM全面生产维护,Learning Objectives,Learn a method to:Integrate operational productivity factors applicable in process industr
9、ies in a single comprehensive measurementEliminate factors contributing to equipment failureImprove accessibility for cleaning and maintaining equipmentUse predictive maintenance as a diagnostic toolImplement maintenance audits,TPM全面生产维护,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
10、程性能的主要因素其因果系统的理解工作策略;,TPM全面生产维护,Whats in It for Me?,Optimized process operations and maintenanceA method to replace the traditional approach of detecting and correcting faulty conditions as they occurA proactive system which monitors and corrects causesAn operations strategy based on understanding t
11、he cause and effect system affecting the major contributors to process performance,TPM全面生产维护,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。,TPM全面生产维护,Total Productive Maintenance (TPM),TPM DefinitionA common sense approach to monitor operations, maintain equipment, eliminate unscheduled d
12、owntime, and improve the level of cooperation between Operations and Maintenance.,TPM全面生产维护,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,TPM全面生产维护,TPM,Achieve zero equipment breakdowns and zero defects through preventionEstablish prevention byMaintaining normal conditionsEarly detection of
13、 abnormalitiesQuick response,TPM全面生产维护,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,TPM全面生产维护,Traditional Approach“Re-Active Maintenance”,Maintenance “WE FIX”Perform all maintenance activitiesPerform “Fire Figh
14、ting” maintenance when a machine breakdown occursOrder and administer all tooling, supplies, etc.Perform Preventive Maintenance,Manufacturing “WE OPERATE”Generally does not perform any maintenance activitiesContacts maintenance when a machine breakdown occursInactive during maintenance activities“Ru
15、n it till it breaks”,TPM全面生产维护,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,TPM全面生产维护,Key Definitions,Preventive Maintenance is a time or usage based method of maintaining equipment. Maintenance act
16、ivities are performed on equipment based on defined time and/or usage intervals to prevent equipment breakdowns from occurring.PM Schedules,Predictive Maintenance is a situation based method of maintaining equipment. Maintenance activities are performed on equipment based on visible signals or diagn
17、ostic techniques to prevent equipment breakdowns from occurring.Vibration AnalysisLaser MeasuringUltrasoundGenerator TestingThermographyOil Analysis,TPM全面生产维护,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,TPM全面生产维护,Present State Analysis
18、and Team Organization,Assess Current Operating ConditionsMachine utilization, productivity, etc.Maintenance repair costs (parts and labor)Prioritize order of TPM effortsAssess capabilities of potential TPM Champions and Team MembersSelect TPM Champion and Team MembersEstablish initial kick-off works
19、hopEstablish team goal,TPM全面生产维护,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,TPM全面生产维护,Typical Operational Process Measurements,Utilization: The ratio of equipment actual operating time to the total available operating time= Ac
20、tual Operating Time/Available TimeEfficiency: The ratio of actual product produced to a standard= (Actual Parts/Hour)/(Standard Part/Hour)Output: Measure of output over a specified time period= lbs/hr, pieces/hr,TPM全面生产维护,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.,TPM全面生产维护,Overall Equi
21、pment Effectiveness,Overall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality product at the designed rate.,TPM全面生产维护,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
22、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.,TPM全面生产维护,OEE Breakdown: The Six Big Losses,Breakdowns and Minor StoppagesMalfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages)SetupAny activit
23、y related to equipment changeover, setup, or cleaning.,IdlingTime equipment is running but not producing product.Speed LossesEquipment operating at less than standard or design speed due to equipment/product abnormality,Quality FactorsActivities related to ensuring the quality of the product produce
24、d on the equipment (in-process checks).Rework LossesThe time taken to re-process product or time take to produce un-usable product.,TPM全面生产维护,六大浪费的识别练习,TPM全面生产维护,Six Big Losses Identification Exercise,TPM全面生产维护,OEE的计算原理,承载时间 (LT),设备运转总的可利用时间 = 40 hrs,可用水平(AL),运行水平 (OL),质量水平 (QL),OEE,73% x 91% x 80%,
25、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%,AL HRS = 40 - 3.1 - 3.8 - 4.2 = 28.9 hrsOL HRS = 28.9 - 3.1 - 1.1 = 26.3 hrsQL HRS = 26.3 - 3.1 - 2.1 = 21.1 hrs,TPM全面生产维护,Calculating OEE Elements,Loading
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