办公室管理部门推行TPM课件.pptx

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1、Total Productive MaintenanceOFFICE 办公室办公室1 ProcessCertificationQCPCRoot Cause/CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinic ActivityTotal Productive Maintenance ACE Office Qualifying Level TPM2 程序验证程序验证全面性生产全面性生产维护维护质量诊断程序质量诊断程序图表图表根本原因根本原因修正行动修正行动减少

2、生产减少生产准备准备标准化标准化作业作业防误措施防误措施市场反馈市场反馈分析分析6S质量诊断质量诊断活动活动全面生产性维护 ACE 办公室合格水平 3Total 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！TPM 全面生产性维护4TPM K

3、ey Concept TPM的重要概念Left neglected.Equipment Breaks Down如果不重视设备很快就会坏TPMs focus is to prevent problems before equipment breaks.TPM 的焦点是要在设备出故障以前以前防止问题出现。In the past,maintenance focusedon 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。5Total Productive Maintenance Total Productive Maintenance

4、 is a New Way of Workingis a New Way of Working全面生产性维护是一种全新的工作方式全面生产性维护是一种全新的工作方式全面生产性维护是一种全新的工作方式全面生产性维护是一种全新的工作方式TPM Attitude:TPM Attitude:TPMTPM态度：态度：态度：态度：“We are all responsible for our“We are all responsible for our equipment.”equipment.”“我们所有人对我们的设备负责。我们所有人对我们的设备负责。我们所有人对我们的设备负责。我们所有人对我们的设备负责

5、。”Old Attitude:Old Attitude:Old Attitude:过去的态度：过去的态度：过去的态度：“I operate,you fix.”“I operate,you fix.”“I operate,you fix.”“我操作，你修理。我操作，你修理。我操作，你修理。”“I fix,you design.”“I fix,you design.”“I fix,you design.”“我处理，你设计。我处理，你设计。我处理，你设计。”“I design,you operate.”“I design,you operate.”“I design,you operate.”“我设

6、计，你操作。我设计，你操作。我设计，你操作。”6Hidden Defects隐藏的问题隐藏的问题Failures故障故障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、形、原材料粘黏、表面磨损、裂缝、过热、震动、

7、噪音及其它不正常现象。震动、噪音及其它不正常现象。Tip of the Iceberg冰山的顶端7ComponentFailure部件失灵Typical Causes of Equipment Breakdown典型的设备故障原因Failure to replace toner更换墨盒失败Paper jam卡纸I wonder whatsgoing to fail next?我想下面还会出什么我想下面还会出什么问题呢？问题呢？Dirt and contamination灰尘和污染Out of paper缺纸8TPM Benefits TPM的益处Reduced maintenance cost

8、s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Improved quality 提高品质E

9、quipment more capable of holding tolerance设备抗性增强Less down time,longer life缩短停工时间，寿命更长9TPM Qualifying Criteria (Business Process/Office)3ACE Element Awareness Training for all employeesoEquipment assessment A,B&CoPM plan for 100%of category“A”equipmentWhats AheadoBRONZE TPM CRITERIAoImplement PM Plan

10、oTrack downtime history for vital machinesoProcess ManagementoIdentify Key ProcessesoIdentify Waste Elimination OpportunitiesQualifyingAwareness&Baseline10TPM 合格标准 (商业程序/办公室)3ACE 内容内容认知培训，针对所有员工认知培训，针对所有员工oA,B&C类类设备评估设备评估o所所有有“A”类设备的类设备的PM计划计划前面前面是什么？是什么？o铜铜牌牌TPM标准标准o执执行行PM计划计划o追追溯重要机器的停工历史记录溯重要机器的停

11、工历史记录o程序程序管理管理o确定确定关键程序关键程序o确定确定浪费消减方法浪费消减方法合格合格认认知知&基基线线11Sullair Safety Lockout Program Procedure寿力安全设备锁定计划程序Lockout Procedures:锁定程序：Actions necessary to lockout a power source of any machine to be repaired,serviced or set-up,where unexpected motion,or an electrical or other energy source,would ca

12、use personal injury or equipment damage.在任何机器的电源需要修理、维护或准备的地方都必须进行锁定，否则意外的动作或其它电源将会引起人身的伤害或设备的损坏。Lockout Tag:锁定标签12WARNING 警告NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.决不要从它人处接受锁定设备的钥匙。决不要从它人处接受锁定设备的钥匙。THE ASSOCIATE RESPONSIBLE FOR APPLYING THE LOCK OR TAG IS THE ONLY PERSON AUTHORIZED TO REMOVE THE LOC

13、K OR TAG.唯唯有经授权负责运用锁或标签的人员可以拿掉该锁或标签。有经授权负责运用锁或标签的人员可以拿掉该锁或标签。Lockout/Tagout Review:锁定锁定/标识检查标识检查13ACTION ITEM 1:Assess All Equipment活动活动内容内容1 1：评估所有设备：评估所有设备By“Equipment”we mean any machine that was a capital expense and has a depreciative value.Or any machine that is important to your cell.所谓“设备”是指

14、任何花费了资金并会贬值的机器。或任何对你的部门重要的机器。We Categorize all Equipment based on how Unique and Critical it is to ensure we focus attention on the right equipment first.Pay special attention to bottleneck equipment.我们根据设备的独特性和重要性对所有设备进行分类，以确保我们的注意力首先放在正确的设备上。对瓶颈设备给予特殊的关注。14?ACTION ITEM 1:Assess All Equipment(cont.

15、)活动活动内容内容1 1：评估所有设备：评估所有设备（待续）（待续）Category A:Category A:Critical equipment for which an alternate machine is not feasible,because:A A类：类：类：类：不能用其它设备替代的关键设备，因为：No alternate exists,or无替代设备，或The alternate is usually unavailable due to utilization,or该替代设备通常正被使用而不能获得，或It would be too costly/time consumin

16、g to transition to the alternate太贵/需花太多时间进行替换 Category C:Category C:Equipment for which it is relatively easy to find a replacement or alternate C C类：类：类：类：相对容易用其它设备替代的设备Includes most off-the-shelf equipment包括最常用的设备Typically cost$2,500费用低于$2,500Standard spare parts(like drive motors)are available of

17、f-the-shelf可获得的常用标准备件（如驱动马达）Category B:Category B:All other equipment/machines B B类：类：类：类：所有其它设备/机器15In addition to machine category,create a table listing all machines and additional categories,such as:除了机器分类，还应作一表格列出所有机器和附加类别，如：Item description/ID number 物品物品描述描述/ID号号Category 种类种类Item Owner 物品物品主人

18、主人Identify equipments title holder and a“local”owner if appropriate确定确定设备名义上的拥有者及一设备名义上的拥有者及一“本地本地”主人，如有必要的话主人，如有必要的话Department managers signature部门部门经理的签名经理的签名ACTION ITEM 1:Assess All Equipment(cont.)活动活动内容内容1 1：评估所有设备：评估所有设备（待续）（待续）Department ManagerCategory A/B/C List A/B/C类类清单清单CopierEpson Print

19、erAir conditionerPersonal Comp.Personal Comp.Personal Comp.Personal Comp.BCACCCCUser NameUser NameUser NameUser NameUser NameUser NameUser NameCo.NameCo.NameCo.NameCo.Name Co.NameCo.NameCo.Name435653217e76544082318921802345 Item物品 ID#Category类型 Title Holder名义主人 Local Owner本地主人16Example:Office Equipm

20、ent Assessment WorksheetTotal Productive Maintenance,Office Equipment Assessment WorksheetNote:Evaluation for machine only.Not for networksEquipment nameDept.Equipment ID#Responsible IndividualProductivity1.How often is the equipment used each day?80%or above5 50-80%3 50%or below22.Is there backup/a

21、lternate equipment available?No(one of a kind)5 Yes(another dept.)3 Yes(in dept)13.To what extent will a failure of this equipment affect other office processes?Stops entire dept.process5 .Do other processes run through this equipment?Slows other dept.processes4 Only affects this machine14.To what e

22、xtent will a failure of this equipment affect on-time delivery?Decisively5 Somewhat2 Not Significantly1Quality5.How will the processes run on this equipment affect final quality of theDecisively5 finished product/service?Somewhat2Not significantly1Maintenance6.What is the average monthly cost of rep

23、airs to this equipment?$1000 or more5$0-$10004Service Contract27.What is the average time it takes to repair this equipment?Over 3 hours5 (Help desk response,if applicable)1-3 hours40-1 hour2Safety,Environment,Housekeeping8.Do safety enhancements need to be applied?Does the equipment need a housekee

24、ping schedule?Both answers are“yes”5One answer is“yes”3“A”Machine:32-40none are yes0“B”Machine:22-31Machine Category:Total Score:“C”Machine:21 or less17范例:办公室设备评估 工作表全面生产性维护,办公室设备评估工作表注意:仅用于机器评估。不用于网络系统。设备名称部门设备ID#负责人员生产力1.该设备第日使用有多频繁?80%或以上5 50-80%3 50%或以下22.有可用的后备/替代设备吗?没有(其中一种)5 是的(另一部门)3 是的(部门内)

25、13.该设备失灵会在多大范围内影响其它设备?阻滞了整个部门的运行5 .其它设备的运行经过该设备吗?减慢了其它部门的运行4 只影响到这台机器14.该设备的失灵会在多大范围内影响正在进行的发送?很明显地5 有些2 不明显1品质5.该设备的运行将怎样影响产品/服务的最终品质?很明显5有些2不明显1维护6.每月花在修理该设备上的平均费用有多少?$1000 或以上5$0-$10004售后服务27.平均花多少时间修理该设备?3小时以上5 (Help desk response,if applicable)1-3 小时40-1 小时2安全、环境和内务管理8.需要增加安全性吗?该设备需要内务管理进度表吗?答案

26、都是“是”5一个答案是“是”3“A”类机器:32-40没有答案是“是”0“B”类机器:22-31 机器机器类型类型:总总分分:“C”类机器:21 或更少18 ACTION ITEM 2:PM Plan on 100%“A”活动活动内容内容2 2：针对所有：针对所有A类机器的类机器的PM计划计划Operator PM defined for 100%of Category A machines.为所有A类机器制定操作员PMqDetermine if there are any“A”machines in your areaq确定你的工作区域是否有A类机器qIf there are,there m

27、ust be a PM plan:q如果有，应有一个PM计划：qIn-house 内部qOutside Contractor 外部合约人Rev:BRevision Date:3/25/98Operator Preventive Maintenance Service CardMachine:Okuma LC-30,4 Axis,BT#3054Daily PM Tasks1.Check running sight.2.Check and fill Waylube:Vactra 2.3.Check tramp oil and scrounger.Empty tramp oil if require

28、d.4.Check and fill coolant:PML 9333.Weekly PM Tasks:Do Daily tasks and the following:1.Check and fill spindle lube:DTE 24.2.Check and fill air lubricator:DTE 24.(Shut off and drain air to fill)3.Check motor fan filter(Change if necessary):Cat.#030058.4.Check and fill hydraulic tank:DTE 24.5.Check ro

29、ll filter(Change if needed):Cat.#027793.Monthly PM Tasks:Do all tasks on this sheet.1.Grease chuck fittings,1 shot.2.Grease 1 fitting,2 shots,both turrets.3.Clean air filter.4.Change air filter:Cat.#021183.19 ACTION ITEM 2:PM Schedule on 50%A&B(contd)活动活动内容内容2 2：针对：针对50%50%A和和B类机器的类机器的PM进度表进度表（待续）（待

30、续）Following is highly recommended to make Operator PM effective:强烈强烈推荐推荐跟进以确保操作员PM的实施：Use a “Visible at-a-glance”system(Such as a color-coded PM Status board)within the work area to indicate the actual status of“Operator PM”tasks.使用一眼就能看见的系统(如使用颜色代码PM状态板)在单元中表明“操作员PM”任务的实际状态lMust be easy to understa

31、ndlNo book or folder to readl必须容易理解l无需翻书或文件夹20What is next?下一步是什么？Complete TPM training of your work group by March 7,20012001年3月7日前你的工作组应完成TPM培训Before the end of February,look for a groupwiseannouncement of a“Drivers”Meeting to discussthe necessary resources and logistics for completingqualifying T

32、PM activities在2月底以前，宣布召开“领导层”会议，讨论必要的资源和后勤以帮助完成取得合格资格的TPM活动21We want a company that reveres people who design,build and maintain things that never break,rather than people who fix things that break.George DavidUTC Chairman and CEO我们希望公司尊敬那些设计、建造并维持不会坏我们希望公司尊敬那些设计、建造并维持不会坏的东西的人们，而不是那些修理会坏的东西的人们。的东西的人

33、们，而不是那些修理会坏的东西的人们。George DavidUTC Chairman and CEOSummary 小结22Total Productive MaintenanceOFFICE 办公办公室室231、有时候读书是一种巧妙地避开思考的方法。4月-234月-23Tuesday,April 25,20232、阅读一切好书如同和过去最杰出的人谈话。01:01:5301:01:5301:014/25/2023 1:01:53 AM3、越是没有本领的就越加自命不凡。4月-2301:01:5301:01Apr-2325-Apr-234、越是无能的人，越喜欢挑剔别人的错儿。01:01:5301:

34、01:5301:01Tuesday,April 25,20235、知人者智，自知者明。胜人者有力，自胜者强。4月-234月-2301:01:5301:01:53April 25,20236、意志坚强的人能把世界放在手中像泥块一样任意揉捏。25四月20231:01:53上午01:01:534月-237、最具挑战性的挑战莫过于提升自我。四月231:01上午4月-2301:01April 25,20238、业余生活要有意义，不要越轨。2023/4/251:01:5301:01:5325 April 20239、一个人即使已登上顶峰，也仍要自强不息。1:01:53上午1:01上午01:01:534月-

35、2310、你要做多大的事情，就该承受多大的压力。4/25/2023 1:01:53 AM01:01:5325-4月-2311、自己要先看得起自己，别人才会看得起你。4/25/2023 1:01 AM4/25/2023 1:01 AM4月-234月-2312、这一秒不放弃，下一秒就会有希望。25-Apr-2325 April 20234月-2313、无论才能知识多么卓著，如果缺乏热情，则无异纸上画饼充饥，无补于事。Tuesday,April 25,202325-Apr-234月-2314、我只是自己不放过自己而已，现在我不会再逼自己眷恋了。4月-2301:01:5325 April 202301:01谢谢大家谢谢大家