2 tpm edit

  • View
    819

  • Download
    3

Embed Size (px)

Transcript

  • Total Productive Maintenance

  • - Total Productive Maintenance (TPM)

    - Maintenance ( )

    - TPM 8

    - 3 Zero

    - 12 TPM

    - KPI TPM (OEE, MTTR, MTBF)

    - 1 TPM, Focus Improvement (FI)

  • ()

    - 16

    - TPM

    - 2 TPM, Autonomous Maintenance (AM)

    - AM, 5, Initial Clean, Detection,

    Vision Control, One Point Lesson - 3 TPM, Planned Maintenance (PM)

    - 4 8 TPM

    - Further Training for TPM (Tools, etc)

    - TPM Award

  • Part - 1

    (Introduction)

  • CASE I

  • ( )

    ()

    ()

    (Preventive Medicine)

  • (OEE)

  • (Maintenance System)

    : 1.

    2.

    3.

    4.

    5.

  • TPM ? TPM

  • : Total

    : Maintenance

    : Productive

  • TPM

    Old Attitude

    I operate, you fix I fix, you design

    I design, you operate

    TPM Attitude

    We are all responsible for our equipment

  • Part - 2

    Maintenance ( )

  • HISTORY OF MAINTENANCE

    < 1950

    Breakdown Maintenance

    1950

    Preventive Maintenance

    1957

    Corrective Maintenance

    MTBF : Mean Time Between Failure

    MTTR : Mean Time To Repair

    1960

    Maintenance Prevention

    Productive Maintenance

    1964

    1971

    TPM

    JIPM TPM Award (Denso)

    1981

    1. Time Based

    2. Condition Based

    1.PM + 2.CM+ 3.MP => PM Awards

  • 1. (Break down Maintenance) :

    2. (Preventive Maintenance) :

    3. (Productive Maintenance) :

  • ()

    4. (Corrective Maintenance) :

    5. (Maintenance Preventive) :

    (Maintenance fee)

  • ()

    6. (Total Productive Maintenance)

    :

  • Part - 3

    TPM 8

  • 8 TPM

  • 8 TPM

    1.

    Ko

    be

    tsu

    Ka

    ize

    n

    2.

    Jis

    hu

    Ho

    ze

    n

    3.

    Pla

    nn

    ed

    ma

    inte

    na

    nce

    4.

    Sk

    ill

    tra

    inin

    g

    5.

    Ea

    rly M

    an

    ag

    em

    en

    t

    6.

    Hin

    sh

    itsu

    Ho

    ze

    n

    7.

    Off

    ice

    im

    pro

    ve

    me

    nt

    8.

    Sa

    fety

    /h

    yg

    ien

    e &

    en

    vir

    on

    me

    nt

    /

    (Fo

    cu

    se

    d

    Imp

    rove

    me

    nt)

    (Au

    ton

    om

    ou

    s

    Main

    ten

    an

    ce)

    Ed

    uca

    tio

    n S

    kil

    l

    Tra

    inin

    g

    (Qu

    ality

    Ma

    inte

    nan

    ce)

    CONSOLIDATION

  • Part - 4

    3 Zero

  • Increasing Failure Rate

    Constant Failure Rate

    Decreasing

    Failure

    Rate

  • (Loss)

    1.

    2.

    3.

    4.

    5.

    6.

  • (Chronic Losses)

    (Sporadic Losses)

  • -

    -

    -

    -

    - .

  • TPM

  • TPM

    ZERO ZERO

    ZERO

    3 ZERO

  • Beyond LOSS

    Throughput Focus

  • Part - 5

    12 TPM

  • CASE I

    (continue)

  • Total Productive

    TPM

    12

    PREPARATION () 3-6 Months

    1. TPM 2. TPM 3. TPM 4. 5. 6.

    IMPLEMENTATION ( ) 3 years

    7. 7.1 ( 1) 7.2 ( 2) 7.3 ( 3) 7.4 ( 4) 8. ( 5) 9. ( 6) 10. ( 7) 11. ( 8)

    IMPROVEMENT & CONSOLIDATION ()

    12. TPM

  • TPM

    12 1 TPM

    2 TPM TPM 3 TPM 4 TPM 6

  • TPM ()

    5 TPM , ,

    6 TPM () 7 7.1 ( 1) 7.2 ( 2) 7.3 ( 3) 7.4 ( 4)

  • TPM ()

    8 ( 5) 9 ( 6)

    10 ( 7) 11 ( 8) 12 TPM

  • TPM

  • TPM

    TPM

  • Part - 6

    KPIs TPM (OEE, MTTR, MTBF)

  • OEE

    Overall Equipment Effectiveness

    (OEE)

  • (Overall Equipment Effectiveness, OEE)

    = x x

  • 1. (Availability Ratio)

    = - x 100

    1 = 460 = 60 ( 20 , 20 , 20 )

    = 400

    = 460 - 60 x 100 = 87% 460

    K = , ,

  • 2. (Performance Ratio) = x x 100%

    1 = 400 = 500 = 0.5 /

    = 0.5 x 500 x 100% 400 = 63%

    K ,

  • 3. (Non-Defectives Ratio)

    = - x 100%

    1 120

    = 500 - 120 x 100% 500 = 76%

    K = , ,

  • (OEE) = x x

    = (0.87 x 0.63 x 0.76) x 100

    = 41.7%

    Total Productive Maintenance

  • MTBF MTTR

    MTBF / 1 (MEAN TIME BETWEEN FAILURE)

    MTTR 1 (MEAN TIME TO REPAIR)

  • MTBF MTTR

    MTBF = -

    MTTR =

  • CASE I

    (continue)

  • Part - 7

    1 TPM (Focus Improvement, FI)

  • FOCUS IMPROVEMENT

  • Focus Improvement

    TPM (Why-why analysis)

  • TPM

  • Part - 8

    16 (16 Losses)

  • Plant-wide Losses (16 losses)

    : Set up Losses

    :

    : (Speed Loss)

    :

    : (Jig & Fixture)

  • 16

    1. ()

  • 16

    2. (Set-up Loss)

    /

    1 Plat form 16

    2 Tundish

    Tundish30

    3 Lock Guide Top Carriage 7

    4 Seal Dam block

    Chamber 1

    5 Guide 1

    6 Dam block 2

    7 Dam block 5 5

    8 Dam block 10

    9 Belt 5

    10 Check Emli Back Up Roll 5

    11 Belt 3

    12 Guide 1

    13 Dam block 6 6

    14 Dam block Chamber 1 1

    15 Gap Dam block 3 3

    No.

    30 16

    7

    10

  • 16

    3. ( Tool)

  • 16

    4.

  • 16

    5.

  • 16

    6.

  • 16

    7.

  • 16

    8.

  • 16

    9.

  • 16

    10.

  • 16

    11. (Speed Loss)

  • 16

    12.

  • 16

    13.

  • 16

    14.

  • 16

    15.

  • 16

    16. , , Jig

  • Plant-wide Losses (16 losses)

    : Set up Losses

    :

    : (Speed Loss)

    :

    : (Jig & Fixture)

  • Part - 9

    TPM

  • Sub-Committee

    1. Focused Improvement P

    ro

    du

    cti

    on

    2. Autonomous Maintenance

    3. Planned Maintenance

    4. Education / Training

    5. Early Management

    6. Quality Maintenance

    7. Office Improvement

    8. Safety / Environment

    Plant Manager

    Ma

    inte

    na

    nce

    QA

    R &

    D

    Perso

    nn

    el

    Acco

    un

    t

    Sa

    le / M

    ark

    et

    Pu

    rch

    ase

    Leader

    Members

  • Part - 10

    2 TPM (Autonomous Maintenance)

  • CASE I

    (continue)

  • x-function group

  • 20~25%

    - - Maintenance Prevention - Re-design - Training - Preventive Maintenance - Overhual etc.

    -

    -

    -

    -

    -

  • DRIVING CONCEPT OF INITIAL CLEAN

    Clean to Inspect,

    Inspect to Detect,

    Detect to Correct,

    Correct to Perfect!

  • THE ROLE OF CLEAN IN AUTONOMOUS MAINTENANCE

  • Autonomous maintenance(AM)

    AM

    Equipment operators

    Accept and share responsibility (with maintenance) for the performance and

    health of their equipment

  • PQCDSM

    1. Initial Clean,

    2. 5-S 3. Managers Model and Pilot Teams. 4. Visual Controls and One Point Lessons.

  • MANAGERS MODEL AND PILOT TEAMS

  • 1 (Minor Flaws)

    2 (Unfulfilled Basic Condition)

    3 (Inaccessible Place)

    7 (Unsafe Places)

    4 (Contamination Sources)

    6 (Unnecessary & Non-urgent items)

    (shock)

    (Grain)

    (Quality Defect Source)

    5

  • Attach this tag to the relevant equipment

    TPMAutonomous Maintenance

    1

    WHITE TAGE(Operator) ABNORMALITY SITE

    2 3 4 5

    Equip. Code : _____________

    Equip. Name : __________________________

    Date found : _____/_____/_____

    Found by : ______________________________

    Description :

    TAG. NO. _____

    Step :

    Attach this tag to the relevant equipment

    TPMAutonomous Maintenance

    1

    RED TAG(Maintenance) ABNORMALITY SITE

    2 3 4 5

    Equip. Code : _____________

    Equip. Name : __________________________

    Date found : _____/_____/_____

    Found by : ______________________________

    Description :

    TAG. NO. _____

    Step :

    Attach this tag to the relevant equipment

    TPMAutonomous Maintenance