TPM方法.pdf

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TPMMETHOD:.
TPM
GLOBALINDICATOR:THETRS
Qualityproductiontime
TRS=
Openingtime
NumberofgoodpartsproducedxCycletime
TRS=
Openingtime
Cycletime=Initialreference+improvements
Initialref.=Minimumtechnicaltime:.
TPM
RELIABILITYINDICATOR
AverageofgoodworkingtimeActualproductiontime
MTBF=
Numberofrealstoppages:.
TPM
RELIABILITYINDICATOR=MTBF(mean
timebetweenfailure)
Itistheaveragedurationinminutesduringwhichthemachineorthe
installationfunctionedwithoutanystoppages.
Thestoppagesare:
-machinebreakdowns
-breakdownsrelatedtotools
-breakdownsrelatedtotheproduct
-stoppagesforchange-overs(usedorbroken)
-stoppagesforfrequentadjustments
-stoppagesforinspection(SPCsampling)
-stoppagesformaintenance
Stoppagesfortoolchange-oversarenottakenintoaccount:.
TPM
BREAKDOWNSANDMICRO-STOPPAGES:
nBREAKDOWNSnMICRO-STOPPAGES
–Stoppages>=5mins–Stoppages<5mins
–Notoften–Often
–Systematicallynoted–Notnoted
–Stoppageaffectsthe–Littleornoperceptionbythegroup
entireworkinggroup–Easystart-upwithouteliminationof
–Interventionofanexpertthecause(suppressionoftheeffect)
–Researchnecessary–Nonidentifiedcauses
beforestart-up–Littlemotivationtoeliminatethem
–Identifiablecausesbecauselittleperceivedimpacton
production
–Stronglyinvolvetheoperatorsand
automaticinstallationpeoplefor
taskswithoutAddedValue:.
TPM
DATACOLLECTIONS
nBREAKDOWNRECORDSOFTHELAST6
MONTHS
nPRODUCTIONNOTEBOOKS
nOPERATOREXPERIENCE
nTHEDATEOFTHELASTTECHNICAL
MODIFICATIONDONEONONEPARTOFTHE
MACHINE:.
TPM:Breakdowns
Paretoanalysisofbreakdowns
–Paretoofunsolvedbreakdownsof
thelast12months
–Eliminatefromthisdatabasethe
solvedbreakdowns
–Priorityistosolvebreakdownsthat
representthehigheststoppages
–Repetitivebreakdownsmustbe
highlighted
breakdown1breakdown3breakdown5
breakdown2breakdown4breakdown6:.
TPM:BREAKDOWNS
TREATMENTMETHODOLOGY
KnowthehistoryofPeopleConcerned
breakdownsandcurrentworkPROCESSMethods
Steering:Supervisor
RegistertheanomaliesExecution:Operators
(includingtheMethod:Recordonanotebook
1
breakdowns)nearthemachineorinstallationas
theyoccur
.
Steering:Supervisor
Execution:MaintenanceProf./0to5mins:GAP
2Carryouttherepairs5to15mins:Tech
WorkshopTechnician
Method:Managementof>15mins:Expert
operationsandspareparts>30mins:Maintenance
3Confirmthecause
Steering:Supervisor
Execution:MaintenanceProf.+TA
+Supervisor
Method:1h30meetingoncea
Definetheactionstoavoidweek,5Whyoreventualcreation
4recurrence
ofaPSG:.
TPM:BREAKDOWNS
TREATMENTMETHODOLOGY
Steering:Supervisor
Execution:MaintenanceProf.+
CreateormodifyifSupervisor
5necessarytheroutine
Method:Updateandvalidationof
sheetofpreventiveroutinesheet.
maintenance
Steering:Supervisor
Execution:Operators+
ApplythenewstandardMaintenanceProf.
6Method:Followingthelevelof
maintenance,definethetraining
needsandtrainthecontributors
Steering:Animationtoreach
objectives
Execution:Applicationofformalised
Thehistoryofbreakdownsistheback-updocumentoftheprocess,instructions
itisfoundonthemachineandisavailableforeverybody.
Itiscompletedbythepersoncarryingoutthegiventask:.
TPM:BREAKDOWNS
WEEKLYMEETING
–SUBJECT:breakdownsencounteredduringtheweek
–PARTICIPANTS:supervisorandmaintenancetechnician
–GOAL:ensurethatthedefinitivemeasureshavebeen
implementedtoavoidanyrecurrenceofbreakdowns
–PLAN:
èweeklybreakdowninventoryforthepastweek
èexaminecauses
èactionstobeimplemented:.
TPM
MICRO-STOPPAGES:CHARACTERISATION
–Shut-down<5mn
–Often
–Norecords
–Littleornoperceptionbythegroup
–Easystart-upwithouteliminationofthecause(suppression
oftheeffect)
–Unidentifiedcause
–Littlemotivationtoeliminatethembecauselittleperceived
impactonproduction
–Stronglyinvolvestheoperatorsandautomaticinstallation
peoplefortaskswithoutAddedValue:.
TPM:MICROSTOPPAGES
TREATMENTMETHODOLOGY
PeopleConcerned
PROCESSMethods
Selectthe
machines
Steering:Supervisor
Registerthemicro-Execution:TechniciansandOperators
1stoppagesMethod:Useofexhaustivefilmofallthemachine
anomalies(withfollow-upofhumanintervention).Pareto
Selectthemicro-stoppage
2tobetreated
Steering:Supervisor
Execution:Operators,Supervisor,Maintenanceand
ManufacturingEngineeringTechnicians
Method:meetingsontheshopfloorwithproblemsolving
Identifythepossibletools(Pareto-BrainStorming-5Mcause-effectdiagram
3
causesofthemicro--5Why's)
stoppage
Steering:Supervisor
4Execution:MaintenanceExpert
Fromthenotedeffect,Method:Formaliseandtraintheoperatorindiagnosis
definethediagnosis
methodofcauses
Steering:Supervisor
5QuantifythecausesExecution:Operators
(counting)Method:Notedonnumberedworkstationform(counting):.
TPM:MICROSTOPPAGES
TREATMENTMETHODOLOGY
Selectthecausestobe
6treatedinpriority
Steering:Supervisor
Execution:PSGmembers
Method:Pareto-Balancing-Brainstorming
7Lookforsolutions
Set-upthesolutions
8
Steering:Supervisor
Execution:ManufacturingEngineeringTechnician-
CreateormodifyifMaintenanceProf.-Operators
necessarytheroutineMethod:Dependingonthelevelofmachine
9
sheetofpreventivemodificationand/orlevelofmaintenance
maintenanceDefinethetrainingneedsandtrainthecontributors
Applythenewstandard
10
Steering:Supervisor
Continuewiththe
11Execution:Operators
"counting"ofcausesof
Method:Notedonworkstationform(counting)
themicro-stoppage:.
TPM
ROLEOFTHEOPERATOR
nPREVENTIVEMAINTENANCE
–Carryoutproductionoperationscorrectlyandsetupthe
machine
èDoinspectionofthemachineeveryday
–Maintaintheperformanceofthemachine
èCleaning,Greasing,Tightening
èApplytheselfmaintenanceroutinesheets
–Communicatewithmaintenancedepartment
èCarryoutthe"counting"ofmicro-stoppageregistrationsheets
èCarryouttherecordingofmicro-stoppagescauses
–Participatewithengineeringandtrialofnewequipment:.
TPM
ROLEOFTHEOPERATOR
nCURATIVEMAINTENANCE
–Preparethemachineconditionsforrepair
–Givetheirfeelingsaboutthemachineandtheiropinions
abouttheworkingconditions
–Assisttechniciansduringrepairandheavymaintenance
–ParticipateinPSGtoidentifysolutionsformicro-stoppage
andbreakdown:.
TPM:MICRO-STOPPAGES
OPERATORTRAINING
nStepsduringwhichthenAcquiredknowledge
operatorbecomes
trained
–Elaborationofcause-effect–Constructionofacause-effect
diagramdiagram,methodologyand
researchofcauses,knowledge
offactorsresponsibleforthe
correctfunctioningofthe
machine
–Diagnosisofthecausesof–Diagnosismethodologyofa
micro-stoppagesmalfunction
–Researchforsolutions–Technicalknowledge
–Creationormodificationof–Knowledgeofmachine
thepreventivemaintenancemaintenanceneeds
routinesheet:.
TPM
ROLEOFTHEMAINTENANCEDEPARTMENT
nPREVENTIVEMAINTENANCE
–Trainandassisttheoperators
–Improvethereliabilityofthemachineandstandardise
identicalequipment
ècapability,features
ècycletime
–Improvemaintainability
–Dotechnicalinspectionthatneedexpertise
–Continuousimprovementofmaintenanceorganization
–Participateintheengineeringofnewequipment:.
TPM
VISUALORGANISATION
nExamplesofvisualmeans
–Positionmarkings(machines,tooling,tools,products,etc.)
–Colourcodingbyfunction,productorworkshop
–Lightpaintondirtyobjects
–Cupboardswithoutdoors
–Etc...:.
TPM:preventivemaintenance
Preventive
maintenanceJanvierFévrierMarsAvrilMaiJuinJuilletSeptembreOctobreNovembreDécembre
procedureVidangemoteur
1Vérification
serragevissupportbâtiserragevissupportbâtiBoardfor
Graissagecarterschedulingthe
Contrôletensionetpreventive
usurecourroie
maintenance
Contrôledimensionnel
3axe
2
ExperienceanalysisWeeklymeetings
3
Machine5
Date:AtelierEnsembleNote:
ConfigurationinitialeConfigurationinitialeNouvelleconfigurationNouvelleconfiguration
4
Historical
Reportoftheaccount
inspectionanomalies
PropertyofValeo-Duplicationprohibited:.
TPM:preventivemaintenance
Workingconditions
Boardordatasheetforschedulingthepreventivemaintenance
JanvierFévrierMarsAvrilMaiJuinJuilletSeptembreOctobreNovembreDécembre
Vidangemoteur
Vérificationserragevissupportbâti
Graissagecarter
Contrôletensionetusurecourroie
Contrôledimensionnelaxe
finished
Tobedone
JLJL
ObservedNothingwrong
defect
PropertyofValeo-Duplicationprohibited:.
EXAMPLES
ObviousTPM
nVisualmarkforMinandMaxlevels
nMarktolocatethestoppositionofamobilepartofa
machine
nRedmarkforpressuremanometer
nImportantscrewswithnuttighteningarerepaired
withvisualmark(see2onpage49)
nGreaselocationsarehighlightedwitharrows,
numberedandcoloured
nPartlistislabelledoncontainers(oiltank,pumpfor
greasingoperations...):.
EXAMPLES
ObviousTPM
1
3
2:.
FIELDAPPLICATION:.
TPM
PILOTWORKSHOP
nCRITERIA
–Lineorbottle-neckmachines(inordertogaincapacityand
availability)
–Presentingalow"MTBF"
–Stronglypenalisingtheflow
–Semi-automaticinstallationsconsistingofmanual
workstations(theactivityoftheoperatordependsuponthe
goodfunctioningoftheinstallation):.
TPM
schedules
nPreliminary"5S"operations
èimplementationofcleaningprocedure
èimplementationofinspectionprocedure
èvisualorganisation
nTPMmethodology
èTRSmeasure
èMTBFmeasure
èTreatmentofbreakdowns
èTreatmentofmicro-stoppages
nComplementthepreventivemaintenance
procedure:.
TPM:MICROSTOPPAGES
TREATMENTMETHODOLOGY
PeopleConcerned
PROCESSMethods
Selectthe
machines
Steering:Supervisor
Recordthemicro-Execution:TechniciansandOperators
1stoppagesMethods:Useofexhaustivefilmofallthemachine
anomalies(withfollow-upofhumanintervention).Pareto
Selectthemicro-stoppage
2tobetreated
Steering:Supervisor
Execution:Operators,Supervisor,Maintenanceand
ManufacturingEngineeringTechnicians
Methods:meetingsontheshopfloorwithproblemsolving
Identifythepossibletools(Pareto-BrainStorming-5Mcause-effectdiagram
3
causesofthemicro--5Why's)
stoppage
Steering:Supervisor
4Execution:MaintenanceExpert
Fromthenotedeffect,Methods:Formaliseandtraintheoperatorindiagnosis
definethediagnosis
methodofcauses
Steering:Supervisor
5QuantifythecausesExecution:Operators
(counting)Methods:Notedonnumberedworkstationform
(counting):.
TPM:MICROSTOPPAGES
TREATMENTMETHODOLOGY
Selectthecausestotreat
6
inprioritySteering:PSGLeader
Execution:PSGteammembers
Method:Pareto-Balancing-Brainstorming
Lookforsolutions
7
Set-upthesolutions
8
Steering:Maintenance,ManufacturingEngineering
Execution:ManufacturingEngineeringTechnician-
CreateormodifyifMaintenanceProf.-Operators
necessarythepreventiveMethod:Dependingonlevelofmachinemodification
9maintenanceroutinesheetand/orlevelofmaintenance
Definethetrainingneedsandtrainthecontributors
10Applythenews