1、 IWPE 99 JinanTotal Normalized Productive Maintenance- TNPM 全員規(guī)范化生產(chǎn)維修李葆文 Li Baowen廣州大學(xué) Guangzhou University廣州，小北登峰麓景路，510091第1頁(yè)，共25頁(yè)。 IWPE 99 Jinan什么是TPM？ What is TPM ?全效率 O E E 全系統(tǒng) Whole System 全 員 All Members Participating第2頁(yè)，共25頁(yè)。TPM大行動(dòng)TPM ACTION空間、時(shí)間全系統(tǒng)SPACE，TIME，THE WHOLE SYSTEM設(shè)備管理靠全員ALL MEMBE

2、RS PARTICIPATING提高效率才成功SUCCESS RELIES ON OEE INCLRESING第3頁(yè)，共25頁(yè)。What is The Most Difficult Point to Implement TPM in China ? 什么是在中國(guó)推行TPM的最難點(diǎn)？ 全 員參加 All Members Participating 第4頁(yè)，共25頁(yè)?！?全員” 這一理念對(duì)不對(duì)？ “ All members participating”, right or wrong? 有人說：“ 設(shè)備維修是維修工人的事，這么先進(jìn)的設(shè)備讓只會(huì)操作的操作工人去維修，簡(jiǎn)直是胡鬧！” Somebody

3、said:” It is a nonsense that the advanced equipment is repaired by the operator who knows only operating” 第5頁(yè)，共25頁(yè)。We need to change our traditional thinking pattern !我們應(yīng)該改變傳統(tǒng)的心智模式！What effects our thinking pattern?什么影響著我們的心智模式？經(jīng)驗(yàn),教訓(xùn), 歷史, 習(xí)慣,理論experience, teaching, history, habit, theory, 第6頁(yè)，共25頁(yè)。“

4、 Clear to zero.” Let s change our thinking pattern .讓我們改變自己的心智模式。不斷的使自己思想進(jìn)入“ 歸零” 狀態(tài)。第7頁(yè)，共25頁(yè)。EVEN ANIMAL HAS HIS THINKING PATERN.即使動(dòng)物都有自己的心智模式什么拴住了大象？WHAT FASTENS THE PITY ELEPHANT？是細(xì)細(xì)的繩子和棍子？IS THE THIN ROPE OR BAR？ NO！不是！ THE THINKING PATERN OF THE ELEPHANT！ 是大象的心智模式！第8頁(yè)，共25頁(yè)。What is the failure? 什

5、么是故障？故障的語源：故障是人 故 意使 設(shè)備產(chǎn)生 障 礙的。 According to the linguistic source of “ failure” in Chinese, it is the people who break down the machine on purpose.第9頁(yè)，共25頁(yè)。Worker is the mother of the machine, machine is a baby who can not say. 工人是設(shè)備的母親，設(shè)備是不會(huì)說話的嬰兒。 如果每個(gè)員工象母親對(duì)待自己不會(huì)說話的嬰 兒那樣對(duì)待和關(guān)心設(shè)備，設(shè)備就是健康寶寶。 If the op

6、erator is concerned with and pay close attention to his equipment like the mother toward her son, then the equipment will certainly be a healthy baby.第10頁(yè)，共25頁(yè)。故障是冰山的頂峰。The failure is the peak of an iceberg. failure 故障 dirt 臟污 heating 發(fā)熱 vibrating 振動(dòng) leaking 滴漏 loosening 松動(dòng) short-circuit 短路 aging 老化

7、 softening 軟化 deforming 變形 冰山下面這么多潛在問題，不靠“ 全員” 關(guān)注行不行？第11頁(yè)，共25頁(yè)。Why should we repair a control box of an overhead travelling crane for more than 40 times a month ?為什么天車的控制盒一個(gè)月要修理40多次？因?yàn)椋翰僮鞴と税芽刂坪袃?nèi)的導(dǎo)線拉斷， 或把控制盒沾上水而短路。Since, the wire inside the control box is drawn out or made short-circuit by putting in

8、to the water carelessly by operators. + , -第12頁(yè)，共25頁(yè)。Fault always begins from minor problems. 故障總是從小處開始的。飛機(jī)失事很少會(huì)是飛機(jī)頭或機(jī)翼掉下來，往往是油管堵塞或是某一個(gè)小螺絲松落。The airplane accident is seldom caused by the cracking down of the head or the wing, but always by the lost of a small nut or the block of an oil pipe.第13頁(yè)，共25

9、頁(yè)。為什么在中國(guó)企業(yè)安裝TPM會(huì)更困難？WHY IS IT MORE DIFFICULT TO INSTALL TPM IN CHINESE COMPANIES？歷史文化不同；DIFFERENT HISTORY AND CULTURE；企業(yè)員工平均素質(zhì)不同；DIFFERENT AVERAGE PERSONNEL QUALIFICATION；管理模式不同；DIFFERENT PATERN OF MANAGEMENT。第14頁(yè)，共25頁(yè)。TPM 在中國(guó)企業(yè)安裝應(yīng)適應(yīng)中國(guó)企業(yè)文化TPM should be re-tailored to suit the body of Chinese compani

10、es.The comparison of enterprise culture in different countries. 中外企業(yè)文化比較 項(xiàng)目 日本企業(yè) 美國(guó)企業(yè) 中國(guó)企業(yè) item Japanese company American company Chinese company 員工素質(zhì) 高，平均 高， 參差不齊 低，參差不齊 qualification high, same high, different low , different 團(tuán)隊(duì)合作 好，同舟共濟(jì) 一般，有獨(dú)立性 差，無形組織 cooperation good so so, independent bad, invi

11、sible group 職業(yè)道德 優(yōu)秀 良好 一般 responsibility excellent good general 流動(dòng)性 低 高 較低 mobility lower high low第15頁(yè)，共25頁(yè)。A successful TPM installed in Chinese company, three problems should be solved. 中國(guó)企業(yè)成功的TPM，應(yīng)解決好三個(gè)問題：1 工人素質(zhì)行不行？Is the capability of operators suitable to TPM ?2 工人愿意不愿意？Will the operators want

12、join TPM activities ?3 制度允許不允許？Do the rules and regulations permit operators to participate TPM activities ?第16頁(yè)，共25頁(yè)。如何解決？- 規(guī)范HOW TO SOLVE THE PROBLEM- NORMALIZATION規(guī)范：根據(jù)企業(yè)設(shè)備實(shí)際，員工素質(zhì)而制訂的工作規(guī)程和行為準(zhǔn)則。THE WORKING PROGRAM AND THE BEHAVIOR REGULATION ACCORDING TO THE REALITY OF EQUIPMENT AND OPERATORS QUAL

13、ITY第17頁(yè)，共25頁(yè)。解決方案 規(guī)范 SOLUTION - NORMALIZATION1 Capability: Training, education, but can not meet the requirement immediately build appropriate behavior normalization on maintenance，training.1 員工素質(zhì)：靠培訓(xùn)，教育，但不可能很快達(dá)到要求 制訂適應(yīng)員工水平的維修行為規(guī)范，培訓(xùn)上崗。第18頁(yè)，共25頁(yè)。解決方案 規(guī)范 SOLUTION - NORMALIZATION2 Willingness: company

14、 culture, education and promoting, but sometime, distant water cannot quench present thirst. Normalization is the inner law of company, that everybody should obey.2 愿意：靠企業(yè)文化，教育，宣傳，但有時(shí)遠(yuǎn)水 解不了近渴。規(guī)范就是企業(yè)內(nèi)部的家法，每個(gè)人都要遵守。第19頁(yè)，共25頁(yè)。解決方案 規(guī)范 SOLUTION - NORMALIZATION3 Regulation: can be changed to meet the requi

15、rement of TPM. In other words, if the operator maintain the equipment according to the normalization, then the regulation permits.3 制度：制度當(dāng)然可以改變以適應(yīng)TPM的 需要。也就是說，只要按照規(guī)范執(zhí)行， 制度就是支持（允許）的。第20頁(yè)，共25頁(yè)。The difference between normalization and standard規(guī)范與標(biāo)準(zhǔn)有什么不同？1 規(guī)范是企業(yè)內(nèi)部規(guī)定，不同企業(yè)可以有所不同。而標(biāo)準(zhǔn)則是跨行業(yè)、跨企業(yè)的。2 規(guī)范是動(dòng)態(tài)可調(diào)的，應(yīng)

16、隨設(shè)備進(jìn)步，人員素質(zhì)進(jìn)步及時(shí)加以調(diào)整。標(biāo)準(zhǔn)則有相對(duì)較長(zhǎng)時(shí)間的穩(wěn)定性。1 Normalization is the inner regulation, different companies may have different normalization. However, standard is trans-company or trans-trade, standard is true to every company.2 Normalization is dynamic and changeable, the normalization can be alternated along w

17、ith the progress of personnel and equipment. However, the standard is stable in a longer period.第21頁(yè)，共25頁(yè)。規(guī)范與 ISO貫標(biāo)THE RELATIONSHIP BETWEEN NORMALIZATION AND ISO STANDARDIZATION規(guī)范與ISO貫標(biāo)目標(biāo)一致Having the same destination規(guī)范是ISO標(biāo)準(zhǔn)的深入和細(xì)化Normalization is the detail of ISO standardizationTPM的規(guī)范化文件相當(dāng)于ISO貫標(biāo)的C級(jí)

18、，D級(jí)文件The document of TPM normalization belongs to class C or D documentent of ISO standardization第22頁(yè)，共25頁(yè)。規(guī)范化的內(nèi)容THE CONTENTENT OF NORMALIZATION現(xiàn)場(chǎng)管理規(guī)范化 On-site maintenance備件管理規(guī)范化 Spare parts management前期管理規(guī)范化 Earlier stage management維修管理規(guī)范化 Maintenance management潤(rùn)滑管理規(guī)范化 Lubrication management臺(tái)帳管理規(guī)范化 Files management第23頁(yè)，共25頁(yè)。什么是TNPM？WH