自主維護(hù)介紹

2011-11-19Agenda自主維護(hù)愿景自主維護(hù)目的與益處自主維護(hù)的推進(jìn)自主維護(hù)團(tuán)隊(duì)及RACI自主維護(hù)MCRSAgenda自主維護(hù)愿景自主維護(hù)目的與益處自主維護(hù)的推進(jìn)自主維護(hù)團(tuán)隊(duì)及RACI自主維護(hù)MCRSAutonomousMaintenance-Vision

自主維護(hù)-愿景

自已的設(shè)備自已維護(hù)自主維護(hù)是每個(gè)操作人員對(duì)自已所操作的設(shè)備進(jìn)行日常的清潔，檢查，潤(rùn)滑，配件代替，修復(fù)，故障診斷，精確的檢查，關(guān)注他所操作設(shè)備的一切。目的在于“自己把自己的設(shè)備保持在良好的狀態(tài)”

Time時(shí)間NumberofLabels/Abnormalities標(biāo)記／異常的數(shù)量GreaterparticipationoftheOperator操作工更多的參入AutonomousMaintenance-Vision

自主維護(hù)-愿景BlueLabels–MaintenancebyOperators藍(lán)色標(biāo)記－維護(hù)工作由操作工完成RedLabels–Maintenancebytechnicals

紅色標(biāo)記－維護(hù)工作由維修工完成Agenda自主維護(hù)愿景自主維護(hù)目的與益處自主維護(hù)的推進(jìn)自主維護(hù)團(tuán)隊(duì)及RACI自主維護(hù)MCRS生產(chǎn)問(wèn)題總是存在是因?yàn)?-低估了設(shè)備問(wèn)題導(dǎo)致的生產(chǎn)損失 -缺少技能 -缺少對(duì)異常問(wèn)題的快速響應(yīng) -缺少對(duì)問(wèn)題的了解 -缺少找到異常問(wèn)題的能力 -缺少找到周邊隱藏的異常問(wèn)題的能力為了獲得解決這些問(wèn)題的條件，操作工必須首先要能夠發(fā)現(xiàn)設(shè)備的異常

1.判別正常和異常的能力2.維持正常條件下的控制能力3.對(duì)異常問(wèn)題的快速且正確的處理能力為什么自主維護(hù)？維護(hù)指導(dǎo)書(shū)的改變

-從目前的CIL到自主維護(hù)紅色模塊.操作維修人員成為主要設(shè)備的主人-我的機(jī)器我自己關(guān)照消除設(shè)備的主要損失和改善設(shè)備的效率,質(zhì)量和費(fèi)用.-發(fā)現(xiàn)異常和缺陷,并通過(guò)單個(gè)的操作人員/小組和團(tuán)隊(duì)行為來(lái)改善自主維護(hù)轉(zhuǎn)變通過(guò)正確的操作和對(duì)關(guān)鍵點(diǎn)的每天檢查避免設(shè)備損壞由操作工對(duì)設(shè)備良好的管理和維修使設(shè)備處在理想的狀態(tài)永久的維護(hù)設(shè)備在良好的狀態(tài)所需建立的基本條件目的Moresafetyduringtheoperation

操作時(shí)更安全MoreSAFETY更安全What?-BENEFITS實(shí)行自主維護(hù)保養(yǎng)的益處

Betterworkenvironment

更好的工作環(huán)境Betterenvironmentatwork更好的工作環(huán)境ThenaturesaysThanksYou

大自然會(huì)對(duì)你說(shuō)謝謝What?-BENEFITS實(shí)行自主維護(hù)保養(yǎng)的益處Increaseofthereliabilityandefficiencyoftheequipment;增加設(shè)備的可靠性和效率IncreasetheEquipmentsLifecycle增加設(shè)備的壽命MoreEfficiency

高效What?-BENEFITS實(shí)行自主維護(hù)保養(yǎng)的益處Withthis,wewillhave:實(shí)現(xiàn)這些，我們會(huì)擁有

更好的技能

可靠性精心維護(hù)取得成效What?-BENEFITS實(shí)行自主維護(hù)保養(yǎng)的益處ROLEOFTHEOPERATOR

操作工的角色AUTONOMOUSMAINTENANCE自主維護(hù)ROLEOFTHEOPERATOR

操作工的角色MACHINESCHANGEWHENMENCHANGE...人的改變將帶來(lái)機(jī)器的改變“ITAKECAREOFMYMACHINE”

“我照顧我的機(jī)器”Agenda自主維護(hù)愿景自主維護(hù)目的與益處自主維護(hù)的推進(jìn)自主維護(hù)團(tuán)隊(duì)及RACI自主維護(hù)MCRSAutonomousMaintenance–Implementationprocess

自主維護(hù)-執(zhí)行過(guò)程

HowtoAdvanceAutonomousMaintenance怎樣去發(fā)展自主維護(hù)Inordertomaintainhigherproductivityequipmentandtocultivateworkerswhoarestrongattheequipmentandcapableofautonomousmaintenance,theVPOautonomousmaintenanceprocessshouldbeimplemented.為了維持設(shè)備高的生產(chǎn)效率，培養(yǎng)工作人員使其有高超的維護(hù)技能，能執(zhí)行自主維護(hù)。VPO自主維護(hù)流程必須執(zhí)行。TheProcesswillbeBasedonfourModules.這個(gè)過(guò)程基于四個(gè)模塊Eachplantwillhaveaimplementationschedule.每個(gè)工廠(chǎng)將有一個(gè)執(zhí)行時(shí)間表EachModulehashisownsupportingmaterial.每個(gè)模塊有它自己的支持材料Attheendofeachmoduleontheequipmentpointofevaluationtheautonomousmaintenance

itwillbeinonelevel.在每個(gè)模塊結(jié)束時(shí),對(duì)設(shè)備所做的自主維護(hù)評(píng)估必須是在同一個(gè)水平上Foreachequipmentwithintheplantwewilldefinetheexpectedleveltobeachieved.在工廠(chǎng)內(nèi)對(duì)每一個(gè)設(shè)備我們可以定義我們希望取得的自主維護(hù)水平Tomovefromonemoduletoanotherforoneequipementanauditmustbedone.一個(gè)設(shè)備如果從一個(gè)模塊升級(jí)到另一個(gè)模塊必需經(jīng)過(guò)審計(jì)AutonomousMaintenance自主維護(hù)VPOBLOCKVPO塊Planning計(jì)劃Fundamental基礎(chǔ)Advanced發(fā)展Consolidation鞏固Time時(shí)間AutonomousMaintenance–Implementationprocess自主維護(hù)-執(zhí)行過(guò)程

(紅黃綠藍(lán))ZBSandtheplantareresponsibletobuildtherolloutplanperplantandforthezone.ZBS和工廠(chǎng)根據(jù)工廠(chǎng)和區(qū)域情況去建立推行計(jì)劃102345675SInitialcleaning初步的清潔工作CountermeasurescausesandEliminationofabnormality原因及對(duì)策及異常消除TentativecriteriaofInspection&Lubrication檢查及潤(rùn)滑的暫定標(biāo)準(zhǔn)Generalinspection一般檢查Autonomousinspection自主檢查Standardization標(biāo)準(zhǔn)化Autonomousmanagement自主管理Milestone里程碑Audits審計(jì)Audits審計(jì)Audits審計(jì)123Stage01一級(jí)Stage02二級(jí)Stage03三級(jí)Stage00級(jí)3-4M2-3M2-3M2-3M6-9M5-7M3-4M共需18個(gè)月10235SInitialcleaning初步的清潔工作CountermeasurescausesandEliminationofabnormality原因及對(duì)策及異常消除TentativecriteriaofInspection&Lubrication檢查及潤(rùn)滑的暫定標(biāo)準(zhǔn)Generalinspection一般檢查武漢現(xiàn)狀A(yù)udits審計(jì)123Stage01一級(jí)Stage02二級(jí)Stage03三級(jí)Stage00級(jí)3-4M2-3M2-3M2-3M6-9M我們還處在黃模塊安裝階段！Agenda自主維護(hù)愿景自主維護(hù)目的與益處自主維護(hù)的推進(jìn)自主維護(hù)團(tuán)隊(duì)及RACI自主維護(hù)MCRSAutonomousMaintenance–StructureDefinition

自主維護(hù)-結(jié)構(gòu)定義PlantManager工廠(chǎng)經(jīng)理AutonomousMaintenanceCoordinator自主維護(hù)協(xié)調(diào)員TSManagerTS經(jīng)理AreaManager區(qū)域經(jīng)理AutonomousMaintenanceAreaSupport自主維護(hù)區(qū)域支持PeopleandManagementSupport員工和經(jīng)理支持MCRS

AutonomousMaintenance–MainFunction

自主維護(hù)-主要功能PlantManager工廠(chǎng)總經(jīng)理AutonomousMaintenanceCoordinator自主維護(hù)協(xié)調(diào)員TSManagerTS經(jīng)理DepartmentalManager部門(mén)經(jīng)理AutonomousMaintenanceAreaSupport自主維護(hù)區(qū)域支持PeopleandManagerSupport員工和經(jīng)理支持OwneroftheAutonomousMaintenanceProcessinPLANT工廠(chǎng)實(shí)施自主維護(hù)工廠(chǎng)的所有者TechnicalSupport(TrainingandExecution)技術(shù)支持（培訓(xùn)和執(zhí)行）OwneroftheAutonomousMaintenanceProcesswithinthedepartment實(shí)施自主維護(hù)部門(mén)的所有者OwneroftheAutonomousMaintenanceProcesswithinthePLANT工廠(chǎng)內(nèi)自主維護(hù)的所有者LinkbetweenAreaxMaintenancexPeople在各部門(mén)，維護(hù)和員工之間進(jìn)行自主維護(hù)的協(xié)調(diào)工作SkillSupport(PeopleandManagement)技能支持（人員和管理）AreaSupport(AutonomousMaintenanceProcess)區(qū)域支持（自主維護(hù)過(guò)程）PeopleandManagementFront人事和管理層AMCommittee自主維護(hù)委員會(huì)MaintenanceCommittee維修委員會(huì)Coordinator協(xié)調(diào)人CoordinatorAction

協(xié)調(diào)人行動(dòng)STRUCTUREOFTHEAUTONOMOUSMAINTENANCECOMMITTEE自主維護(hù)委員會(huì)架構(gòu)MCRS

ProductiveMaintenance生產(chǎn)維護(hù)

Coordinator協(xié)調(diào)員AMCommitteeLeader自主維修委員領(lǐng)導(dǎo)

(PackagingManager包裝經(jīng)理)PMFacilitator自主維修責(zé)任人MaintenanceTechnician維修工AreaAMFacilitator區(qū)域自主維修責(zé)任人Operator操作工AreaSupervisor區(qū)域主管STRUCTUREOFTHEMAINTENANCECOMMITTEE維修委員會(huì)架構(gòu)MCRS

ProductiveMaintenance生產(chǎn)維護(hù)Coordinator協(xié)調(diào)員MaintenanceCommitteeLeader維修委員領(lǐng)導(dǎo)

Maintenance(TS/Pack)Manager工程經(jīng)理PMFacilitator預(yù)防維修協(xié)調(diào)人Maintenance維修Technician計(jì)劃員AMFacilitator自主維修協(xié)調(diào)人Planning計(jì)劃Technician維修工Maintenance維修Supervisor主管StructureoftheTeam團(tuán)隊(duì)的架構(gòu)Supervisor主管TCOperatorTC廠(chǎng)操作工TBOperatorTB操作工

TAOperatorTA操作工MCRSAgenda自主維護(hù)愿景自主維護(hù)目的與益處自主維護(hù)的推進(jìn)自主維護(hù)團(tuán)隊(duì)及RACI自主維護(hù)MCRSTeamMeeting團(tuán)隊(duì)會(huì)議AMCommitteeMeeting自主維修委員會(huì)會(huì)議MaintenanceCommitteeMeeting維修委員會(huì)會(huì)議MCRS維護(hù)支柱模塊介紹AchieveAutonomousmaintenanceperformances(KPIs)

自主維護(hù)目標(biāo)（KPI)

Process/CategoryTarget目標(biāo)Mymachineownership我的設(shè)備100%ownershipmindset（100%的所有權(quán)在操作）5SSustainable5S（良好的5S持續(xù)）Initialcleaning設(shè)備的初始清潔100%byoperators（100%由操作工完成）Lubricationroutines設(shè)備潤(rùn)滑60%~100%byoperators（60%-100%由操作工完成）Routineinspection日常檢查Developchecklistforalloperators’routineinspections（回顧設(shè)備日常檢查項(xiàng)目）OPLDevelopOPLforallcriticalmachine(>1perperson,month)（關(guān)鍵維護(hù)的OPL數(shù)量每人每月1張）Changeover換線(xiàn)操作100%byoperators（100%操作完成）Overhaul維修>25%oftotalO.Hworkhourbyoperators（操作工的維修時(shí)間占總維修時(shí)間>25%)Fillervalvework灌酒機(jī)閥門(mén)工作>75%byop