TotalProductiveMaintenanceOFFICE

辦公室1

ProcessCertificationQCPCRootCause/CorrectiveActionSet-UpReductionStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinicActivityTotalProductiveMaintenance

ACEOfficeQualifyingLevel

TPM2

程序驗(yàn)證全面性生產(chǎn)維護(hù)質(zhì)量診斷程序圖表根本原因修正行動(dòng)減少生產(chǎn)準(zhǔn)備標(biāo)準(zhǔn)化作業(yè)防誤措施市場反饋分析6S質(zhì)量診斷活動(dòng)全面生產(chǎn)性維護(hù)ACE辦公室合格水平

3TotalProductiveMaintenanceisanequipmentmanagementstrategythatimprovesequipmentefficiency.全面生產(chǎn)性維護(hù)是一種設(shè)備管理策略以提高設(shè)備效率。Or,inotherwords...Treatingtheequipmentlikeitisyourown!或者，換句話說…….對(duì)待設(shè)備就象它是你自己的一樣！TPM全面生產(chǎn)性維護(hù)4TPMKeyConceptTPM的重要概念Leftneglected...EquipmentBreaksDown如果不重視…設(shè)備很快就會(huì)壞TPM’sfocusistopreventproblemsbeforeequipmentbreaks.TPM的焦點(diǎn)是要在設(shè)備出故障以前防止問題出現(xiàn)。Inthepast,maintenancefocused

on

fixingequipmentafteritbroke.過去，維護(hù)工作總是集中在設(shè)備壞了以后對(duì)其進(jìn)行修理。5TotalProductiveMaintenance

isaNewWayofWorking

全面生產(chǎn)性維護(hù)是一種全新的工作方式TPMAttitude:TPM態(tài)度：“Weareallresponsibleforourequipment.”“我們所有人對(duì)我們的設(shè)備負(fù)責(zé)。”O(jiān)ldAttitude:過去的態(tài)度：“Ioperate,youfix.”“我操作，你修理?！薄癐fix,youdesign.”“我處理，你設(shè)計(jì)?！薄癐design,youoperate.”“我設(shè)計(jì)，你操作?！?Afailureisjustthetipoftheiceberg!HiddenDefects隱藏的問題Failures故障Wear,play,slackness,leakage,dust,dirt,corrosion,deformation,adherenceofrawmaterials,surfacedamage,cracking,overheating,vibration,noise,andotherabnormalities.磨損、松馳、泄露、灰塵、污垢、腐蝕變形、原材料粘黏、表面磨損、裂縫、過熱、震動(dòng)、噪音及其它不正?，F(xiàn)象。TipoftheIceberg

冰山的頂端7ComponentFailure部件失靈TypicalCausesofEquipmentBreakdown

典型的設(shè)備故障原因Failuretoreplacetoner更換墨盒失敗Paperjam卡紙Iwonderwhat’sgoingtofailnext?我想下面還會(huì)出什么問題呢？Dirtandcontamination灰塵和污染Outofpaper缺紙8TPMBenefitsTPM的益處Reducedmaintenancecosts減少維護(hù)費(fèi)用Breakdownmaintenanceis10timesmorecostlythanplannedmaintenance故障維修費(fèi)用是有計(jì)劃進(jìn)行維護(hù)費(fèi)用的10倍以上Enhancedsafety提高安全性Findexposedwires,openbelts,missingguards,loosehardware發(fā)現(xiàn)暴露在外的電線、松開的安全帶、缺少防護(hù)、松開的部件Reducedwaste減少浪費(fèi)Preventslossoflubricant,compressedair防止?jié)櫥?、壓縮空氣的浪費(fèi)Improvedquality提高品質(zhì)Equipmentmorecapableofholdingtolerance設(shè)備抗性增強(qiáng)Lessdowntime,longerlife縮短停工時(shí)間，壽命更長9TPMQualifyingCriteria(BusinessProcess/Office)ACEElementAwarenessTrainingforallemployeesEquipmentassessmentA,B&CPMplanfor100%ofcategory“A”equipmentWhat’sAheadBRONZETPMCRITERIAImplementPMPlanTrackdowntimehistoryforvitalmachinesProcessManagementIdentifyKeyProcessesIdentifyWasteEliminationOpportunitiesQualifyingAwareness&Baseline10TPM合格標(biāo)準(zhǔn)

(商業(yè)程序/辦公室)ACE內(nèi)容認(rèn)知培訓(xùn)，針對(duì)所有員工A,B&C類設(shè)備評(píng)估所有“A”類設(shè)備的PM計(jì)劃前面是什么？銅牌TPM標(biāo)準(zhǔn)執(zhí)行PM計(jì)劃追溯重要機(jī)器的停工歷史記錄程序管理確定關(guān)鍵程序確定浪費(fèi)消減方法合格認(rèn)知&基線11SullairSafetyLockout

ProgramProcedure

壽力安全設(shè)備鎖定計(jì)劃程序LockoutProcedures:鎖定程序：Actionsnecessarytolockoutapowersourceofanymachinetoberepaired,servicedorset-up,whereunexpectedmotion,oranelectricalorotherenergysource,wouldcausepersonalinjuryorequipmentdamage.在任何機(jī)器的電源需要修理、維護(hù)或準(zhǔn)備的地方都必須進(jìn)行鎖定，否則意外的動(dòng)作或其它電源將會(huì)引起人身的傷害或設(shè)備的損壞。LockoutTag:鎖定標(biāo)簽12WARNING警告NEVERACCEPTLOCKOUTSKEYSFROMANYONE.決不要從它人處接受鎖定設(shè)備的鑰匙。THEASSOCIATERESPONSIBLEFORAPPLYINGTHELOCKORTAGISTHEONLYPERSONAUTHORIZEDTOREMOVETHELOCKORTAG.唯有經(jīng)授權(quán)負(fù)責(zé)運(yùn)用鎖或標(biāo)簽的人員可以拿掉該鎖或標(biāo)簽。Lockout/TagoutReview:鎖定/標(biāo)識(shí)檢查13ACTIONITEM1:

AssessAllEquipment

活動(dòng)內(nèi)容1：評(píng)估所有設(shè)備By“Equipment”wemeananymachinethatwasacapitalexpenseandhasadepreciativevalue.Oranymachinethatisimportanttoyourcell.所謂“設(shè)備”是指任何花費(fèi)了資金并會(huì)貶值的機(jī)器。或任何對(duì)你的部門重要的機(jī)器。WeCategorizeallEquipmentbasedonhowUniqueandCriticalitistoensurewefocusattentionontherightequipmentfirst.Payspecialattentiontobottleneckequipment.我們根據(jù)設(shè)備的獨(dú)特性和重要性對(duì)所有設(shè)備進(jìn)行分類，以確保我們的注意力首先放在正確的設(shè)備上。對(duì)瓶頸設(shè)備給予特殊的關(guān)注。14?ACTIONITEM1:AssessAllEquipment(cont.)

活動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）CategoryA:

Criticalequipmentforwhichanalternatemachineisnotfeasible,because:A類：不能用其它設(shè)備替代的關(guān)鍵設(shè)備，因?yàn)椋篘oalternateexists,or無替代設(shè)備，或Thealternateisusuallyunavailableduetoutilization,or該替代設(shè)備通常正被使用而不能獲得，或Itwouldbetoocostly/timeconsumingtotransitiontothealternate太貴/需花太多時(shí)間進(jìn)行替換CategoryC:EquipmentforwhichitisrelativelyeasytofindareplacementoralternateC類：相對(duì)容易用其它設(shè)備替代的設(shè)備Includesmostoff-the-shelfequipment包括最常用的設(shè)備Typicallycost<$2,500費(fèi)用低于$2,500Standardspareparts(likedrivemotors)areavailableoff-the-shelf可獲得的常用標(biāo)準(zhǔn)備件（如驅(qū)動(dòng)馬達(dá)）CategoryB:

Allotherequipment/machinesB類：所有其它設(shè)備/機(jī)器15Inadditiontomachinecategory,createatablelistingallmachinesandadditionalcategories,suchas:

除了機(jī)器分類，還應(yīng)作一表格列出所有機(jī)器和附加類別，如：Itemdescription/IDnumber物品描述/ID號(hào)Category種類ItemOwner物品主人Identifyequipment’stitleholderanda“l(fā)ocal”ownerifappropriate確定設(shè)備名義上的擁有者及一“本地”主人，如有必要的話Departmentmanager’ssignature部門經(jīng)理的簽名ACTIONITEM1:AssessAllEquipment(cont.)

活動(dòng)內(nèi)容1：評(píng)估所有設(shè)備（待續(xù)）DepartmentManagerCategoryA/B/CListA/B/C類清單CopierEpsonPrinterAirconditionerPersonalComp.PersonalComp.PersonalComp.PersonalComp.BCACCCCUserNameUserNameUserNameUserNameUserNameUserNameUserNameCo.NameCo.NameCo.NameCo.NameCo.NameCo.NameCo.Name435653217e76544082318921802345

Item物品ID#Category類型TitleHolder名義主人LocalOwner本地主人16Example:OfficeEquipmentAssessment WorksheetTotalProductiveMaintenance,OfficeEquipmentAssessmentWorksheetNote:Evaluationformachineonly.NotfornetworksEquipmentnameDept.EquipmentID#ResponsibleIndividualProductivity1.Howoftenistheequipmentusedeachday? 80%orabove 5 50-80% 3 50%orbelow 22.Istherebackup/alternateequipmentavailable? No(oneofakind) 5 Yes(anotherdept.) 3 Yes(indept) 13.Towhatextentwillafailureofthisequipmentaffectotherofficeprocesses? Stopsentiredept.process 5.Dootherprocessesrunthroughthisequipment? Slowsotherdept.processes 4 Onlyaffectsthismachine 14.Towhatextentwillafailureofthisequipmentaffecton-timedelivery? Decisively 5 Somewhat 2 NotSignificantly 1Quality5.Howwilltheprocessesrunonthisequipmentaffectfinalqualityofthe Decisively 5finishedproduct/service? Somewhat 2 Notsignificantly 1Maintenance6.Whatistheaveragemonthlycostofrepairstothisequipment? $1000ormore 5 $0-$1000 4 ServiceContract 27.Whatistheaveragetimeittakestorepairthisequipment? Over3hours 5(Helpdeskresponse,ifapplicable) 1-3hours 4 0-1hour 2Safety,Environment,Housekeeping8.Dosafetyenhancementsneedtobeapplied?Doestheequipmentneedahousekeepingschedule? Bothanswersare“yes” 5 Oneansweris“yes” 3“A”Machine: 32-40 noneareyes 0“B”Machine: 22-31 MachineCategory: TotalScore:“C”Machine: 21orless 17范例:

辦公室設(shè)備評(píng)估

工作表全面生產(chǎn)性維護(hù),辦公室設(shè)備評(píng)估工作表注意:僅用于機(jī)器評(píng)估。

不用于網(wǎng)絡(luò)系統(tǒng)。設(shè)備名稱部門設(shè)備ID#負(fù)責(zé)人員生產(chǎn)力1.該設(shè)備第日使用有多頻繁? 80%或以上 5 50-80% 3 50%或以下 22.有可用的后備/替代設(shè)備嗎? 沒有(其中一種) 5

是的(另一部門) 3

是的(部門內(nèi)) 13.該設(shè)備失靈會(huì)在多大范圍內(nèi)影響其它設(shè)備? 阻滯了整個(gè)部門的運(yùn)行 5.其它設(shè)備的運(yùn)行經(jīng)過該設(shè)備嗎? 減慢了其它部門的運(yùn)行 4

只影響到這臺(tái)機(jī)器 14.該設(shè)備的失靈會(huì)在多大范圍內(nèi)影響正在進(jìn)行的發(fā)送? 很明顯地 5

有些 2

不明顯 1品質(zhì)5.該設(shè)備的運(yùn)行將怎樣影響產(chǎn)品/服務(wù)的最終品質(zhì)? 很明顯 5

有些 2

不明顯 1維護(hù)6.每月花在修理該設(shè)備上的平均費(fèi)用有多少? $1000或以上 5 $0-$1000 4

售后服務(wù) 27.平均花多少時(shí)間修理該設(shè)備? 3小時(shí)以上 5(Helpdeskresponse,ifapplicable) 1-3小時(shí) 4 0-1小時(shí) 2安全、環(huán)境和內(nèi)務(wù)管理8.需要增加安全性嗎?該設(shè)備需要內(nèi)務(wù)管理進(jìn)度表嗎? 答案都是“是” 5

一個(gè)答案是“是” 3“A”類機(jī)器: 32-40 沒有答案是“是” 0“B”類機(jī)器: 22-31 機(jī)器類型: 總分:“C”類機(jī)器: 21或更少

18

ACTIONITEM2:PMPlanon100%“A”

活動(dòng)內(nèi)容2：針對(duì)所有A類機(jī)器的PM計(jì)劃OperatorPMdefinedfor100%ofCategoryAmachines.為所有A類機(jī)器制定操作員PMDetermineifthereareany“A”machinesinyourarea確定你的工作區(qū)域是否有A類機(jī)器Ifthereare,theremustbeaPMplan:如果有，應(yīng)有一個(gè)PM計(jì)劃：In-house內(nèi)部OutsideContractor外部合約人Rev:BRevisionDate:3/25/98OperatorPreventiveMaintenanceServiceCardMachine:OkumaLC-30,4Axis,BT#3054DailyPMTasks1.

Checkrunningsight.2.

CheckandfillWaylube:Vactra2.3.

Checktrampoilandscrounger.Emptytrampoilifrequired.4.

Checkandfillcoolant:PML9333.WeeklyPMTasks:DoDailytasksandthefollowing:1.

Checkandfillspindlelube:DTE24.2.

Checkandfillairlubricator:DTE24.(Shutoffanddrainairtofill)3.

Checkmotorfanfilter(Changeifnecessary):Cat.#030058.4.

Checkandfillhydraulictank:DTE24.5.

Checkrollfilter(Changeifneeded):Cat.#027793.MonthlyPMTasks:Doalltasksonthissheet.1.

Greasechuckfittings,1shot.2.

Grease1fitting,2shots,bothturrets.3.

Cleanairfilter.4.

Changeairfilter:Cat.#021183.19

ACTIONITEM2:PMScheduleon50%A&B(cont’d)

活動(dòng)內(nèi)容2：針對(duì)50%A和B類機(jī)器的PM進(jìn)度表（待續(xù)） FollowingishighlyrecommendedtomakeOperatorPM effective:強(qiáng)烈推薦跟進(jìn)以確保操作員PM的實(shí)施：

Usea“Visibleat-a-glance”system(Suchasacolor-codedPMStatusboard)withintheworkareatoindicatetheactualstatusof“OperatorPM”tasks.

使用一眼就能看見的系統(tǒng)(如使用顏色代碼PM狀態(tài)板)在單元中表明“操作員PM”任務(wù)的實(shí)際狀態(tài)MustbeeasytounderstandNobookorfoldertoread必須容易理解無需翻書或文件夾20Whatisnext?

下一步是什么？CompleteTPMtrainingofyourworkgroupbyMarch7,20012001年3月7日前你的工作組應(yīng)完成TPM培訓(xùn)BeforetheendofFebruary,lookforagroupwiseannouncementofa“Driver’s”MeetingtodiscussthenecessaryresourcesandlogisticsforcompletingqualifyingTPMactivities在2月底以前，宣布召開“領(lǐng)導(dǎo)層”會(huì)議，討論必要的資源和后勤以幫助完成取得合格資格的TPM活動(dòng)21

Wewantacompanythatreverespeoplewhodesign,buildandmaintainthingsthatneverbreak,ratherthanpeoplewhofixthingsthatbreak.

GeorgeDavid UTCChairman