10330 : 022186814-6 : 022513969, 022186813 2549 (Final Report)
FACULTY OF ENGINEERING,CHULALONGKORN DEPARTMENT OF INDUSTRIAL
WORKS,MINISTRY OF INDUSTRY 10330 : 022186814-6 : 022513969,
022186813 2549 (Executive Summary Report) FACULTY OF
ENGINEERING,CHULALONGKORN MINISTRY OF INDUSTRY
(Final Report) 2549 10330 : 0-2218-6815-6 ; : 0-2251-3969,
0-2218-6813 11 2 4 2 2 3 1. 2. 3. 4. 5. 6. 1. 7. 2. 8. () 3. ... 9.
() 4. . 10. 5. 11. 6. ... 1
.................................................................................................
1 1.1 ............................................................
1 1.2.......................................................... 2
1.3
.........................................................................
4 1.4
................................................................ 7
1.5 ............................................................. 7
1.6
......................................................................
7 2......................................... 9
2.1........................................... 9 2.2
...................................... 14 2.3
.................................................. 16 3
....................................................... 18 3.1
................................................ 18 3.2
TPM....................... 25 4
.......................................... 32 4.1
...................................................................
32 4.2
.........................................................................
36 4.3
..................................................................
39 4.4 ...................................... 43 () 5
............................................................................
48 5.1(Maintenance Master Plan, MMP)
............................................ 48 5.2(Overall
Equipment Effectiveness, OEE).................................. 48
5.3(Autonomous Maintenance,
AM).............................................. 52 6
....................................... 57 6.1 .. 57 6.2 ... 58
7...................................................................................
67 7.1 ........................................................ 67
7.2
.........................................................................
69 7.3
.........................................................................
71 8 ....................................... 74 8.1 .............
74 8.2 ........................................... 75
8.3....................................................... 75
.................................................................................................
77 () .
............................................................ 79 .
................................. 80 .
.................................... 81 . ................... 82 .
.................................... 83 2.1
.......................................................... 14
2.2................................................. 15 4.1
..................................................................................
42
4.2...............................................................
44 5.1 ............... 50
8.1...............................................................
74 1.1
...............................................................................
4
1.2...............................................................................
7 1.3
............................................................................
7 2.1 ................................................... 11 3.1
OEE 6 big losses................................................ 28
4.1 ... 39 4.2 ..................................................
41 5.1 ............... 51 7.1
..................................................................
72 7.2
........................................................................
73 8.1............................................. 75
8.2.........................................................................
76 1 1.1 1.1.1 1) 1 3 2 5 (Total Productive Maintenance, TPM) 2 1
2) 4 4.1 4.2 3) 6 9 (.. 25442549) 6.1 6.2 1.1.2 (TotalProductive
Maintenance, TPM) 1.1.3 49/2548 1,181,800.00 31 2548 28 2549 1.2
1.2.1 1) 2) 3) 4) 1.2.2 1) 10 2) 10 3) 50 1.3 1.1 1. 1 2. / / 3.
TPM 2 TPM, PM, AM 1.1 () 4. 10 10 5. 5 50 50 - - 6. - 50 50 10 50
--- 4 10 7. 1 4 1.1 () : 1 8. 9. 10 10 10. 150 50 11. 12. 1.4 1) 2)
3) 1.5 1.2 1. . 2. (1) 3. (2) 4. 1.6 1.3 .................. 1. 1.3
() .................. 2. 3. TPM 4. 10 5. 5 50 6. - 10 50 - 4 7. 8.
9. 10 10. 150 11. 12. 2 2.1 2 2.1.1 TPM, RCM 1) (Total Productive
Maintenance: TPM)TPM TPM TPM (Availability) TPM (Downtime) 2)
Reliability-Centered Maintenance (RCM) RCM RCM (Reliability Theory)
(Reliability) 1 RCM TPM RCM (Terotechnology) (AssetManagement) 2
Terotechnology (EconomicLifeCycleCost) AssetManagement 2.1.2 2.1 (
Failure-Based Maintenance, FBM) FBM FBM (CM)FBM ( ) (Use-Based
Maintenance, UBM) UBM (Fixed-Period Maintenance) (FailureRateType)
(Condition-Based Maintenance, CBM) CBM
(Inspection-BasedMaintenance,IBM) IBM CBM 2.1 () (Opportunity-Based
Policy) SHUTDOWN (Design-Out Maintenance, DOM)DOM 1.1.1 1.1.2 1)
(Planned Maintenance) (Availability) (Maintainability) TPM 2)
(Predictive Maintenance) (Condition-Based Maintenance) Preventive
Maintenance Daily Maintenance, Periodic Maintenance (Time-Based
Maintenance) (ConditionBased) Over Maintenance 3) (Autonomous
Maintenance) 2.2 2.1 2.1 ( ,2546) 2.2 2.2 ( , 2546) 2.3 3 MRP
(ManufacturingResourcePlanning),JIT(Just-In-Time)
OPT(OptimisedProduction Technology) 1) MRP MRP MRP
(BufferInventory) MRP JobShop 2) JIT JIT JIT Safety Stock MRP
(Buffer Stocks)JIT JIT TPM3) OPT OPT MRP JIT OPT JIT MRP 3 3.1
3.1.1 3.1.1.1 (Installation of a TPM program in a Caribbean plant)
(Perez-Lafont, 1997) (TotalProductiveMaintenance,TPM)
(OverallEquipment Effectiveness, OEE) 1 6 2 3.1.1.2 (Implementation
of TPM in cellular manufacture) (Chand Shirvani, 2000)
(Totalproductivemaintenance,TPM) (Total qualitymanagement,TQM)
(Continuous-flow) 6 o o o o o o (Overallequipmenteffectiveness,OEE)
(Totaleffectiveequipmentproductivity,TEEP) ( )
(Netequipmenteffectiveness,NEE) 3.1.2 3.1.2.1 ( , 2533) 10 9.5%
9.7% 3.1.2.2 ( , 2534) 0.5445 67.68% 3.1.2.3 ( , 2536) 873 16.3%
3.1.2.4 : () ( , 2539) (Connector) 3.1.2.5 ( , 2543) 2 3.1.2.5.1
3.1.2.5.2 3 (Key performance indicators, KPIs)1) Maintenance cost
per production cost Maintenance budgeting variance 2) Overall
equipment effectiveness (OEE)3)
Preventivemaintenanceratio,Maintenanceplannedandscheduledratio,Breakdown
maintenance ratio Maintenance work coverage by work order system
ratio 3.1.3 3.1.3.1 /3 ( , 2543) (SAP-PM) SAP-PM SAP (QFD) SAP-PM
SAP-PM Master Data Transaction Data 3.1.3.2 ( , 2544) 3.1.3.3 ( ,
2546) (OEEApplication) . . 2 OEE 3.1.3.4 ( , 2546) 2 3.1.3.5 ( ,
2547) SAP (Systems Applications and Products in Data Processing) 1)
16.52% 2) 3) 4) 5) 3 SAP 2 30 15 30 / 3.2 TPM 3 6 3.2.1 6
(6BigLosses) (Overall Equipment Effectiveness, OEE)
BreakdownMaintenance (BM) Preventive Maintenance (PM) 2 BM PM QCD Q
C D Q C D TPM Q C D 6Biglosses OEE () 3.2.1.1 6 big losses OEE
3.2.1.1.1 6 big losses 6 1) 2) 3) 4) 5) 6) 6Biglosses Dispatch Lot
6 Big losses 6Biglosses 3.2.1.1.2 6 big losses OEE
(OverallEquipmentEffectiveness,OEE) OEE 3 Availability (A)
Performance Rate (P) Good Quality Rate (Q) A P Q 6 big losses 3.1
3.1 OEE 6 big losses 2 1,200 - - 100.00% 1,200 0.03 34,534 86.34%
4,354 87.39% 75.45%3 1,200 328 - 72.67% 872 0.03 25,127 86.45%
3,207 87.24% 54.80%4 1,200 - - 100.00% 1,200 0.03 35,019 87.55%
3,189 90.89% 79.58%5 1,200 480 - 60.00% 720 0.03 15,853 66.05%
2,113 86.67% 34.35%7 1,440 353 233 59.31% 854 0.03 24,413 85.76%
3,338 86.33% 43.91%8 1,440 60 - 95.83% 1,380 0.03 40,320 87.65%
5,170 87.18% 73.23%9 1,200 33 360 67.25% 807 0.03 28,321 105.28%
3,701 86.93% 61.55%10 1,440 20 - 98.61% 1,420 0.03 41,513 87.70%
5,288 87.26% 75.47%11 1,440 - - 100.00% 1,440 0.03 40,721 84.84%
6,301 84.53% 71.71%12 1,440 - - 100.00% 1,440 0.03 39,017 81.29%
5,842 85.03% 69.11%14 1,440 - - 100.00% 1,440 0.03 40,514 84.40%
7,739 80.90% 68.28%15 1,440 - - 100.00% 1,440 0.03 38,019 79.21%
5,914 84.44% 66.89%16 1,440 - - 100.00% 1,440 0.03 17,223 35.88%
4,173 75.77% 27.19%17 1,200 - - 100.00% 1,200 0.03 22,513 56.28%
4,183 81.42% 45.83%18 960 - - 100.00% 960 0.03 22,011 68.78% 4,511
79.51% 54.69%19 960 - - 100.00% 960 0.03 24,816 77.55% 5,743 76.86%
59.60%21 960 - - 100.00% 960 0.03 21,274 66.48% 6,809 67.99%
45.20%22 960 - - 100.00% 960 0.03 25,519 79.75% 5,374 78.94%
62.95%23 960 - - 100.00% 960 0.03 26,126 81.64% 3,986 84.74%
69.19%24 960 - 360 62.50% 600 0.03 26,123 130.62% 4,553 82.57%
67.41%25 960 - - 100.00% 960 0.03 19,219 60.06% 3,649 81.01%
48.66%26 1,440 - - 100.00% 1,440 0.03 38,024 79.22% 5,384 85.84%
68.00%28 1,440 - - 100.00% 1,440 0.03 40,534 84.45% 3,772 90.69%
76.59%29 1,440 - - 100.00% 1,440 0.03 37,552 78.23% 3,832 89.80%
70.25%30 1,440 - - 100.00% 1,440 0.03 40,043 83.42% 3,773 90.58%
75.56%31 1,440 - - 100.00% 1,440 0.03 40,024 83.38% 4,224 89.45%
74.58%32,640 1,274 953 93.18% 30,413 0.03 804,372 79.34% 120,122
85.07% 62.89% SetupBreak Down1 Loading Time (min.)2 Downtime
(min.)Performance EfficiencyRate of Quality
EfficiencyOEE.Availability3 Operation Time (min.)4 Ideal Cylcle
Time (min/pc.)7 ()8 () 6biglosses OEE 1 3.2.1.2 OEE Q C D OEE QD
(C) 3.2.1.3 TPM pilot area 1 OEE 1 6biglosses OEE TPM AM 6 big
losses OEE OEE 3 6biglosses OEE e-mail 3.2.2 (Maintenance Master
Plan, MMP) 3.2.2.1 1) 2) 3 5 3) 4) 5) 3.2.2.2 1) ( ) 2) 3) 4) ( 2)
5) 6) 7) ( ) 8) 9) 4 2 3 3 1) 2) 3) 2 4.1 40 19 1) ... 2) () 3) ...
4) . 5) 6) 7) 8) 9) () 10) 11) 12) 13) 14) 15) 16) 17) 18) .. 19)
... 11 1) ... : : : : : 180,000 : 120,000 2) () : : : : 3) ... : :
: CNC EDM: : 80% : 60% 4) . : : : : : 5,000 : 4,400 5) : : : : :
150 : 100 6) : : : : : 320,000 : 310,000 7) : : : Boiler : : 3,300
: 3,700 8) () : : : : : 25 : 21 9) : : : CNC : : 168 : 110 10) : :
: Finishing Line : : 1,200,000 : 1,400,000 11) : : : : : 53,000 :
52,845 1) 2) 3) 4) 5) 6) 1) 2) 3) 4) 5) 6) 4.2 4.2.1 4.2.2 SMEs 1)
QCD 2) 3) () 6 AvailabilityPerformance GoodQualityRate OEE
Quality(Q)Cost(C) Delivery(D) 4.2.3 6 Big Losses OEE
(AutonomousMaintenance)1 2 hand-onexperience 4.1 4.1 25482549
.............. 1. 2. 2 3. 4 2 2 4.1 4.3 3 4.3.1 (Preventive
Maintenance Program) 4.3.2 (TotalProductiveMaintenance,TPM)
6(6BigLosses) (Overall Equipment Effectiveness, OEE) OEE 8 TPM (8
Pillars for TPM) 7 (Autonomous Maintenance 7 Steps) 12 (Autonomous
Maintenance Steps 1 and 2) 4.2 4.2 1 9.00 12.00 . 6 (6 Big losses)
(Overallequipment effectiveness, OEE) 13.00 16.00 .
(Autonomousmaintenance,AM) () (Autonomousmaintenance,AM) () 2 9.00
12.00 . 13.00 16.00 . (Maintenancemasterplan, MMP) 1) 6 Big Losses
OEE 2) Autonomous Maintenance 1 2 3)MTBFMTTR 4)(ActivityBoard)
(Maintenance Master Plan) (OEE) (Autonomous Maintenance) 4.1 4.4
4.4.1 6 Big Losses OEE 1) 2) 6 Big Losses Breakdowno o machine
downtime maintenance downtime o o Setup o setup o setup Adjustmento
adjustment oadjustment loss loss o adjustment loss Speed loss o o o
Idleo idle o idle Minor Stoppage o minor stoppage o idle minor
stoppage o minor stoppage oproduct defect o rework, second grade
defect o defect o defect o o setup o o 6biglosses 2 (breakdown)
losses losses losses losses losses A4 3) OEE OEE o (8 480 ) o 6 big
losses OEE o losses 6 o A, P Q 6 big losses OEE o A,P,Q OEE
products o 6 big losses A, P, Q OEE A4 4.4.2 Autonomous Maintenance
1 2 1) 1 2 2) Shut down 1-2 AM Step 1 2 AM Step 1 2 o o- o AM Step
1 2 o 3) AM Step 1 oShut down ( power ) o o () o o AM Step 2 o o o
o o 4) AMStep1 2 5) AM o AMStep1 2 o AM Step 3 o AM Step 3 o o o 8
AM Step 1 2 o o o o 4.4.3 Activity Board 1) Activity board Activity
board update Activity board Activity board 2) Activity board one
point lesson 5 5.1 (Maintenance Master Plan, MMP) 1) 2) 3) 4) 5) 6)
7) 8) 9) (Overhaul) 5.2 (OverallEquipmentEffectiveness, OEE) 5.2.1
3 1) (Availability,A) 2) (Performance, P) 3) (Quality,Q) (Lot) 85%
5.1 % 87% 100 460 60 - 460% 100 = == % 50% 100 400 400 - / 0.5% 100
= == % 98% 100 400 8 - 400% 100 - = = = 5.2.2 6 (6Big losses) 5.1 (
) 5.2.3 1) 2) 6 (6 Big losses) 3) 6 4) 5) 6) 7) 5.3 (Autonomous
Maintenance, AM) 5.3.1 (Basicequipmentcondition) (Small group
activity) 5.3.2 1) ( ) 2) 3) ( ) Crossfunction smallgroupactivities
5.3.3
Workerdorepeatsimpleworkallthetimewithoutanyknowledgeaboutthestructure
andfunctionofeithertheequipmentthey are operating on the product
they are manufacture,and
indoingso,theyarenotexpectedtoconsiderorjudge anything during their
routine work.
Operatorworkeratlastareliberatedfromsimpleandmonotomousrepetitiveworkand
engage in truly human work Knowledgeable operator the importance
aspect is the skill in detecting signs of losses (not an operator
who can fix equipment as well as a maintenance technician) 7 1)
(Abnormality) Cleaning is inspection 2) (Abnormality) 3) 1 2
(Basicequipmentcondition) 4) 3 5) 3 4 (Minor deviation from normal
or optional conditions) 6) 7)
Knowledgeableoperatorsconductautonomoussupervision
andfollowthestandardssetbythemselvesontheorderlyshopfloor,whereanydeviationfrom
normal or optional operating conditions is detected at a glance by
any one 7 1 1 (Modelequipment) 3-5 5.3.4 () 5.3.4.1 1) 1, 2 3 2) 3)
3 4) 5.3.4.2 ( ) 2 5.3.4.2.1 1) 2) 3) 4) 5) 5.3.4.2.2 1 1) Lock out
2) 1 3) (Abnormality) 4) 5) 6) 7) 4 8) 2 2 1) 2) 4 3) 5 Why QC
Tools P-M Analysis 4) Marking Autonomation Tag Etc. 3 1) ( ) 1 2 (
Why ) 5W 2H 2) ( ) 1 2 5W 2H 3) 2 4) 5) 6) One-point-lessons 7) 8)
9) / 6 6.1 2 1) (Maintenance Master Plan, MMP) . 2) 6 (6Biglosses)
(OverallEquipmentEffectiveness,OEE) (AutonomousMaintenance,AM) . 11
4 2 E-mail 6.2 6.2.1 ... 1) (Checklist) (Maintenance report)
Screwcompressor 2) 6 6 6 6 3) Air compressor 1 2 1 2 6.2.2 () 1) 2)
6 6 6 3) 1 2 6.2.3 ... 1) 2) 6 CNC Plasticinjectionmolding 6 6 3)
CNC Plasticinjectionmolding 1 2 6.2.4 . 1) 2) 6 1 6 6 3) 1 1 2 1 2
6.2.5 1) Press40 Milling Grinder 2) 6 Presshighspeed 6 6 3) Press
high speed 1 2 3 6.2.6 1) Compressor 2) 6 K4 6 6 6 3) K4 1 2 K2
6.2.7 1) CCM Boiler 2) 6 6 6 6 3) 1 2 6.2.8 () 1) 2) 6
(Availability, A) 3) 6.2.9 1) (Overhaul) 2) 6 CNC 6 6 6 3) 1 2 3
6.2.10 1) ABC 2) 6 6 6 6 6 6 3) 1 2 SOP 6.2.11 1) Boiler 2) 6
Peeler 3 6 6 6 Chipper 3) Peeler 7 7.1 ... .. . () ... () .. () ...
() () .. . . () () .. 9 () () () () () 7.2 7.2.1 19 2549 177 95 82
82 2 .. 5 3 3 1 1 4 2 1 3 () 1 5 6 3 2 3 () 3 2 3 2 3 3 3 3 3 () 2
() 2 1 ... 3 () 1 1 ... 2 7.2.2 2 1) 6 2) 3 ... 9.00 - 10.45. TPM .
10.45 - 12.00. (Maintenance Master Plan) . 12.00 - 13.00. 13.00 -
14.45. 2 14.45 - 15.00. - 15.00 - 15.45. 1 15.45 - 16.00. . 7.3 .
7.1 1. (Maintenance Master Plan) 2.253.42 2. 2.133.30 3.
(Autonomous Maintenance) 2.323.38 4. 2.383.34 5. (Overall Equipment
Effectiveness : OEE) 2.343.38 6. OEE 2.043.42 7. 6 (Six Big Losses)
1.753.28 8. 6 1.773.30 9. (Total Productive Maintenance : TPM)
1.913.28 10. TPM 1.943.17 :1 = 2 = 3 = 4 = 5 = 7.2 1. (Maintenance
Master Plan) 2.843.76 2. 2.783.39 3. (Autonomous Maintenance)
3.223.57 4. 2.843.61 5. (Overall Equipment Effectiveness : OEE)
2.503.63 6. OEE 2.103.39 7. 6 (Six Big Losses) 2.243.65 8. 6
2.193.49 9. (Total Productive Maintenance : TPM) 2.523.47 10. TPM
2.643.47 :1 = 2 = 3 = 4 = 5 = 8 8.1 1) 8.1 2) 3) 4) 5) 6) 8.2 1) 2)
3) 4) 8.3 19 2549 8.1 79.31% 81.03% 8.2 42.31% 11.54% 7.69% 3.85%
15.38% 7.69% 3.85% . ., . 2534. . . 2 ().: ..., 2546. , ..: , 2548.
, ..: , 2549. . ., . 2533. . ., . 2546. . ., . 2544. . . 2.: ,
2546. . ., . 2543. ,. TPM . . 4.: (-), 2542. . . , . 2546. .. , .
2536. . /3 ., . 2543. . . , . 2547. .: () ., . 2539. Chand,G.,
andShirvani,B.Implementation of TPM in cellular manufacture.Journal
of Materials Processing Technology 103 (2000): 149-154.
Perez-Lafont,J.L.Installation of a TPM program in a Caribbean
plant.Computers ind. Engng 33 (1997): 315-318.
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