Total Productive Maintenance
OFFICE 办公室
Process
Certification
QCPC
Root Cause /
Corrective
Action
Set-Up
Reduction
Standard
Work
Mistake
Proofing
Market
Feedback
Analysis
6S
Quality
Clinic Activity
Total Productive Maintenance
ACE Office Qualifying Level
TPM
程序验证
全面性生产
维护
质量诊断程序
图表
根本原因
修正行动
减少生产
准备
标准化
作业
防误措施
市场反馈
分析
6S
质量诊断
活动
全面生产性维护
ACE 办公室合格水平
TPM 全面生产性维护
Total 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 Key Concept TPM的重要概念
Left neglected... Equipment Breaks Down
如果不重视…设备很快就会坏
TPM’s focus is to prevent problems before equipment breaks.
TPM 的焦点是要在设备出故障以前防止问题出现。
In the past, maintenance focused on 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。
Total Productive Maintenance
is a New Way of Working
全面生产性维护是一种全新的工作方式
Old Attitude:
过去的态度：
“I operate, you fix.”
“我操作，你修理。”
“I fix, you design.”
“我处理，你设计。”
“I design, you operate.”
“我设计，你操作。”
TPM Attitude:
TPM态度：
“We are all responsible for our equipment.”
“我们所有人对我们的设备负责。”
Tip of the Iceberg
冰山的顶端
Hidden
Defects
隐藏的问题
Failures
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、腐蚀变形、原材料粘黏、表面磨损、裂缝、过热、震动、噪音及其它不正常现象。
Typical Causes of Equipment Breakdown
典型的设备故障原因
Component
Failure
部件失灵
Failure to replace toner
更换墨盒失败
Paper jam
卡纸
I wonder what’s
going to fail next?
我想下面还会出什么
问题呢？
Dirt and contamination
灰尘和污染
Out of paper
缺纸
TPM Benefits TPM的益处
Reduced maintenance costs
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
Equipment 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
TPM Qualifying Criteria (Business Process/Office)
ACE Element Awareness Training for all employees
Equipment assessment A,B & C
PM plan for 100% of category “A” equipment
What’s Ahead
BRONZE TPM CRITERIA
Implement PM Plan
Track downtime history for vital machines
Process Management
Identify Key Processes
Identify Waste Elimination Opportunities
Qualifying
Awareness &
Baseline
TPM 合格标准
(商业程序/办公室)
ACE 内容认知培训，针对所有员工
A,B & C类设备评估
所有“A”类设备的PM计划
前面是什么？
铜牌TPM标准
执行PM计划
追溯重要机器的停工历史记录
程序管理
确定关键程序
确定浪费消减方法
合格
认知 &
基线
Sullair 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 cause 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
WARNING 警告
NEVER ACCEPT LOCKOUTS KEYS FROM ANYONE.
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 LOCK OR TAG.
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。
Lockout/Tagout Review:
锁定/标识检查
ACTION ITEM 1: Assess All Equipment
活动内容1：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。
ACTION ITEM 1: Assess All Equipment(cont.)
活动内容1：评估所有设备（待续）
Category A: Critical equipment for which an alternate machine is not feasible, because:
A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 consuming to transition to the alternate
太贵/需花太多时间进行替换
Category C: Equipment for which it is relatively easy to find a replacement or alternate
C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$2,500
Standard spare parts (like drive motors) are available off-the-shelf
可获得的常用标准备件（如驱动马达）
Category B: All other equipment/machines
B类：所有其它设备/机器
?
ACTION ITEM 1: Assess All Equipment(cont.)
活动内容1：评估所有设备（待续）
In 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 物品描述/ID号
Category 种类
Item Owner 物品主人
Identify equipment’s title holder and a “local” owner if appropriate
确定设备名义上的拥有者及一“本地”主人，如有必要的话
Department manager’s signature
部门经理的签名
Department Manager
Category A/B/C List A/B/C类清单
Copier
Epson Printer
Air conditioner
Personal Comp.
Personal Comp.
Personal Comp.
Personal Comp.
B
C
A
C
C
C
C
User Name
User Name
User Name
User Name
User Name
User Name
User Name
Co. Name
Co. Name
Co. Name
Co. Name
Co. Name
Co. Name
Co. Name
43565
3217
e7654
4082
3189
2180
2345
Item物品 ID# Category类型 Title Holder名义主人 Local Owner本地主人
Example: Office Equipment Assessment Worksheet
Total Productive Maintenance, Office Equipment Assessment Worksheet
Note:Evaluation for machine only. Not for networks
Equipment name
Dept.
Equipment ID #
Responsible Individual
Productivity
1. How often is the equipment used each day? 80% or above 5
50-80% 3
50% or below 2
2. Is there backup/alternate equipment available? No (one of a kind) 5
Yes (another dept.) 3
Yes (in dept) 1
3. To what extent will a failure of this equipment affect other office processes? Stops entire dept. process 5
. Do other processes run through this equipment? Slows other dept. processes 4
Only affects this machine 1
4. To what extent will a failure of this equipment affect on-time delivery? Decisively 5
Somewhat 2
Not Significantly 1
Quality
5. How will the processes run on this equipment affect final quality of the Decisively 5
finished product / service? Somewhat 2
Not significantly 1
Maintenance
6. What is the average monthly cost of repairs to this equipment? $1000 or more 5
$0 - $1000 4
Service Contract 2
7. What is the average time it takes to repair this equipment? Over 3 hours 5
(Help desk response, if applicable) 1 - 3 hours 4
0 - 1 hour 2
Safety, Environment, Housekeeping
8. Do safety enhancements need to be applied? Does the equipment need a housekeeping schedule? Both answers are “yes” 5
One answer is “yes” 3
“A” Machine: 32-40 none are yes 0
“B” Machine: 22-31 Machine Category: Total Score:
“C” Machine: 21 or less
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 2
2. 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) 1
3. 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 1
4. 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 - $1000 4
售后服务 2
7. 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 4
0 - 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 机器类型: 总分:
“C” 类机器: 21 或更少
ACTION ITEM 2: PM Plan on 100% “A”
活动内容2：针对所有A类机器的PM计划
Operator PM defined for 100% of Category A machines.
为所有A类机器制定操作员PM
Determine if there are any “A” machines in your area
确定你的工作区域是否有A类机器
If there are, there must be a PM plan:
如果有，应有一个PM计划：
In-house 内部
Outside Contractor 外部合约人
Rev: B
Revision Date: 3/
25/98
Operator Preventive Maintenance Service Card
Machine:
Okuma LC-30, 4 Axis, BT # 3054
Daily PM Tasks
1.
Check running sight.
2.
Check and fill Waylube: Vactra 2.
3.
Check tramp oil and scrounger. Empty tramp oil if required.
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 roll 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.
ACTION ITEM 2:PM Schedule on 50% A&B(cont’d)
活动内容2：针对50%A和B类机器的PM进度表（待续）
Following is highly recommended to make Operator PM effective:
强烈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
Must be easy to understand
No book or folder to read
必须容易理解
无需翻书或文件夹
What is next?
下一步是什么？
Complete TPM training of your work group
by March 7, 2001
2001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 groupwise
announcement of a “Driver’s” Meeting to discuss
the necessary resources and logistics for completing
qualifying TPM 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
Summary 小结
We want a company that reveres people who design, build and maintain things that never break, rather than people who fix things that break.
George David
UTC Chairman and CEO
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。
George David
UTC Chairman and CEO
Total Productive Maintenance
OFFICE 办公室
Ask: What are the 2 major causes of all equipment breakdowns?
Answer:
1. Contamination
2. Lack of lubrication.
For the purpose of ACE, only machines with Brass Tags are considered “Equipment”
