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Total Productive Maintenance全 员 生 产 保 全
Total Productive Maintenance 全员生产保全 Meaning of TPM 全员生产保全之意义 A Japanese Kaizen Strategy focus on
improving the efficiency of machine to gain the overall profit of the company. 为日本的改善策略活动之一种，着眼于改进 机器设备的效率，以提升公司整体的利益。
Total Productive Maintenance 全员生产保全 Features of TPM TPM 之特徵
Emphasize overall company efficiency 着重企业整体的效率化
Achieve Zero Defect, Zero Accident, Zero Shutdown 追求零不良、零灾害、零故障
Involve all departments,Production, R&D, Marketing 包含所有部门，生产、开发、营业部门
All employees participation, from CEO to operator 从总经理到作业员均参与
Kaizen by Small Group Activities 以小团队活动来进行改善
Total Productive Maintenance 全员生产保全 Benefits of implementing TPM TPM 之目的
Reduce shutdown time to deliver product on time 减少停机，交期准时
Stabilize Machine Capability to assure quality level 稳定性能，确保质量
Increase Overall Equipment Efficiency to reduce cost 提升效率，降低成本
Upgrade operation skills to guarantee safety 提升技能，保证安全
Total Productive Maintenance 全员生产保全 Level of Maintenance 保全的境界
BM : Breakdown Maintenance 事后保全 PM : Preventive Maintenance 预防保全 CM : Corrective Maintenance 改良保全 MP : Maintenance Prevention 保全预防
Total Productive Maintenance 全员生产保全 6 Pillars of TPM TPM 六大支柱
User’s Maintenance 自主保全 Planned Maintenance 计划保全 Case Correction 个别改善 Initial Management 初期管理 Easier Manufacturing 易制设计 Education Training 教育训练
Total Productive Maintenance 全员生产保全 Relationship between Pillars and Levels 支柱与境界之关连
Breakdown 事后Maintenance 保全
User’s Maintenance 自主保全Planned Maintenance 计划保全Case Correction 个别改善
Education Training 教育训练
Initial Management 初期管理Easier Manufacturing 易制设计
Preventive 预防Maintenance 保全Corrective 改良Maintenance 保全Maintenance 保全Prevention 预防
Total Productive Maintenance 全员生产保全 6 Major Losses of Machine 设备六大损失
Equipment Breakdown 故障损失 Minor Stoppage 瞬停损失 Changeover/Adjustment 换模损失 Defects/Rework 不良损失 Speed Reduction 退化损失 Waiting Operation 等待损失
Total Productive Maintenance 全员生产保全 Relationship among Losses, Pillars and Job Function (1/2) 损失、支柱与职务之关连 (1/2)
Losses 损失 Pillars 支柱 Equipment Breakdown 故障损失 User’s Maintenance 自主保全
Planned Maintenance 计划保全Case Correction 个别改善
Education Training 教育训练
Initial Management 初期管理Easier Manufacturing 易制设计
Minor Stoppage 瞬停损失Changeover Adjustment 换模损失Defect Rework 不良损失Speed Reduction 退化损失Waiting Operation 等待损失
Total Productive Maintenance 全员生产保全 Relationship among Losses, Pillars and Job Function (2/2) 损失、支柱与职务之关连 (2/2)
Pillars 支柱 Job 职务 User’s Maintenance 自主保全 Operator 作业员
Supervisor 线 长Maintenance Technician 保全员
Consultant 顾 问
Maintenance Engineer 工程师Develop Engineer 开 发
Planned Maintenance 计划保全Case Correction 个别改善
Easier Manufacturing 易制设计Initial Management 初期管理
Education Training 教育训练
Total Productive Maintenance 全员生产保全 Measures for Equipment 设备绩效衡量指标
Overall Equipment Efficiency 设备总合效率 (可动率 ) Measure of the available, performance and quality
efficiency of equipment 衡量设备的时间、性能及质量之效率
Mean Time Between Failures 平均故障间隔时间 Mean Frequency Of Failure 平均故障次数
Measure of the reliability of equipment 衡量设备的可靠能力
Mean Time To Repair 平均修护时间 Measure of the maintainability of equipment
衡量设备的维修能力
Total Productive Maintenance 全员生产保全 Definition of OEE(1/2) 设备总合效率之定义
OEE 可动率 = Equipment Available Efficiency 设备时间效率 x Performance Efficiency 性能效率 x Quality Efficiency 质量效率Equipment Available Efficiency 设备时间效率 :
• Loss of breakdown 故障损失• Loss of changeover 换模损失• Loss of inspection 检查损失• Loss of waiting 等待损失
Total Productive Maintenance 全员生产保全 Definition of OEE(2/2) 设备总合效率之定义
Performance Efficiency 性能效率 : Loss of minor stoppage 瞬停损失 Loss of dummy running 空转损失 Loss of speed reducing 退化损失
Quality Efficiency 质量效率 :
• Loss of defects 不良损失• Loss of rework 重修损失• Loss of retest 重测损失
Total Productive Maintenance 全员生产保全 Calculation of OEE 可动率的算法 (1/2)
(A) Total Time a day 每日时间 = 60min 分 x 24Hrs 小时 = 1440min 分(B) Planned Shutdown Time 计划停机时间 = 480min 分 b1) Break Time 休息时间 = 60min 分 x 2 = 120min 分 b2) Preventive Maintenance 预防保全时间 = 60min 分 x 2 = 120min 分 b3) No Order Waiting Time 无定单等待时间 = 60min 分 x 4 = 240min 分(C) Production Scheduled Time 生产计划时间 (=A-B) = 960min 分(D) Unscheduled Down Time 意外停止时间 = 100min 分 d1) Breakdown 故障 = 20min 分 d2) Changeover/Set up/Adjustment 换模 / 安装 / 调整 =40min 分 d3) Tools Change/Inspection 刀具更换 / 检查 = 30min 分 d4) Waiting Operator/Materials 等待人员 / 材料 = 10min 分
Total Productive Maintenance 全员生产保全 Calculation of OEE 可动率的算法 (2/2)
(E) Available Operation Time 有效生产时间 (=C-D) = 860 min 分(F) Equipment Available Efficiency 设备时间效率 ( = E/C = 860/960 ) = 89.6%(G) Total Output Quantity 全部生产数量 ( = 1450 pcs 个 )(H) Ideal Cycle Time 理论周期时间 ( = 0.5 min 分 /pc 个 )(I) Equipment Performance /Efficiency 设备性能效率 ｛ = (G x H)/E ｝ = 84.3 %(J) Total Rejected Quantity 总不良数 = 200 pcs 个(K) Equipment Quality Efficiency 設備品質效率 ｛ = (G -J)/G ｝ = 86.2 %(J) OEE 可动率 = F x I x K = 89.6% x 84.3% x 86.2% = 65.1% or 或者 = (G-J) x H/C = 65.1%
Total Productive Maintenance 全员生产保全 What is User’s Maintenance 何谓自主保全
The user of equipment is responsible for some basic maintenance activities of equipment 由使用机器设备的操作者，负责从事 一些机器设备的基本保全工作之意。
Total Productive Maintenance 全员生产保全 Objectives of User’s Maintenance 自主保全之目的
Increase the user’s care on equipment. 提升操作者对设备的关心度
Increase the user’s capability to operate equipment 提升操作者对设备的操作能力
Increase the user’s capability to find out the abnormal situation of equipment earlier. 提升操作者能早期发觉设备异常状况之能力
To increase the reliability and OEE of equipment. 提升设备的可靠能力及提升设备的可动率
Total Productive Maintenance 全员生产保全 Seven Steps of User’s Maintenance 自主保全展开七步骤
1) Initial cleaning and check 初期清扫点检2) Elimination of sources of contamination 排除困难发生源头3) Establish standards of cleaning and lubrication 作成清扫及润滑基准4) Implement general inspection and training 实施总点检及技能教育5) Implement inspection by user 实施自主点检6) Implement quality assurance 实施质量保证7) Maintain standards and continue improvement 自主维持管理及提升水平
Purpose 目的Learn the teamwork activities and leadership skills
学习团队活动及领导技能Learn the concept of “cleaning means check”
学习 “ 清扫即是点检 ” 之观念Learn the safety operation procedure
学习安全操作程序Expose the abnormal condition of equipment and correction 找出设备异常之处及复原
Total Productive Maintenance 全员生产保全 Step 1 of User’s Maintenance (1/2) 自主保全第一步骤 (1/2)
Initial cleaning and check 初期清扫点检
Main Activities 主要活動 Remove unneeded parts 设备不要之物移走Clean equipment 清扫设备Discover abnormal condition 发觉异常之处
* List of difficult cleaning 清扫困难表 * List of unstable condition 不佳状态表 * List of query 疑惑一览表 * List of contamination source 污染源头表
Correct the abnormal condition 复元异常之处 * Red Tag for abnormal condition 异常之处贴上膏药单 ( 红单 )
Total Productive Maintenance 全员生产保全 Step 1 of User’s Maintenance (2/2) 自主保全第一步骤 (2/2)
Initial cleaning and check 初期清扫点检
Purpose 目的Learn the basic skills of maintenance 学习基本保全技能Learn the corrective skills for abnormal condition
学习 矫正异常 之技巧Increase reliability of equipment by reducing contamination 减少设备污染，以提升可靠性Keep equipment always in clean condition to increase maintainability 保持设备清洁状态，以提升保全性Improve equipment to be easier for clean and check
改善设备使容易清扫及点检
Total Productive Maintenance 全员生产保全 Step 2 of User’s Maintenance (1/2) 自主保全第二步骤 (1/2)
Elimination of Difficulties 排除困难发生源头
Main Activities 主要活动Eliminate difficult cleaning area
排除清扫困难处所Prevent contamination
防止污染飞散对策Improve the efficiency of clean and check
提升清扫及点检效率
Total Productive Maintenance 全员生产保全 Step 2 of User’s Maintenance (2/2) 自主保全第二步骤 (2/2)
Elimination of Difficulties 排除困难发生源头
Total Productive Maintenance 全员生产保全 One – Point - Lesson 每日一课
Purpose 目的 Use as a training tools for operators, technicians and
engineer 做为作业员、维修员、工程师的训练教材 Share and transfer the Kaizen Skills of equipment
分享及传承对设备的改善技巧 Key Points for Writing 写作要点
– Short in single page 简短一页完成– Better use drawings, picture or diagrams 最好使用 绘图、照片方式– 10 minutes or less for presentation 能在 10 分钟内讲解完成
Purpose 目的Learn to establish maintenance standards
学习自己制定保全标准Realize the importance of adhering to standards
了解遵守标准之重要性Maintain basic condition of equipment to prevent deterioration 维持设备基本条件，防止劣化Apply visual management skills 实施目视管理
Total Productive Maintenance 全员生产保全 Step 3 of User’s Maintenance (1/2) 自主保全第三步骤 (1/2)
Establish Standards of Cleaning and Lubrication 做 成 清 扫 及 润 滑 基 准
Main Activities 主要活动Develop standards of cleaning and lubrication
发展清扫及润滑基准Shorten the time of cleaning and lubrication
缩短清扫及润滑时间Visual management for easier lubrication
容易润滑之目视化Train the skills of cleaning and lubrication
训练清扫及润滑之技巧
Total Productive Maintenance 全员生产保全 Step 3 of User’s Maintenance (2/2) 自主保全第三步骤 (2/2)
Establish Standards of Cleaning and Lubrication 做 成 清 扫 及 润 滑 基 准
Purpose 目的Learn the knowledge and skill of checking equipment
学习有关设备点检的知识及技巧Learn the skills of restoration and improvement
学习设备复原及改善技巧More application of visual management skills 目视管理技巧的深层应用Maintain and improve routine check activities to increase reliability of equipment
做好及改进日常点检活动，以提升设备可靠性
Total Productive Maintenance 全员生产保全 Step 4 of User’s Maintenance (1/2) 自主保全第四步骤 (1/2)
Implement general inspection and training 实 施 总 点 检 及 技 能 教 育
Main Activities 主要活动Train the inspection skill for each check item.
对每一点检项目实施点检技能教育训练Implement inspection for all check items.
对所有点检项目，进行点检活动Continue to discover problem areas and to Kaizen. 继续发觉问题及改善Make sure to finish all check items within limited time.
确保能在一定时间内完成点检项目
Total Productive Maintenance 全员生产保全 Step 4 of User’s Maintenance (2/2) 自主保全第四步骤 (2/2)
Implement general inspection and training 实 施 总 点 检 及 技 能 教 育
Purpose 目的 Train to use “five senses” to discover potential problem area.
训练以“五感” 来发觉问题症兆To deploy the Kaizen experience to other equipment.
将设备改善经验推广到其它的设备Discover potential problem areas for earlier correction by daily cleaning and inspection activities.
透 过每日清扫及点检活动，提早发觉潜在问题并矫正
Total Productive Maintenance 全员生产保全 Step 5 of User’s Maintenance (1/2) 自主保全第五步骤 (1/2)
Implement inspection by user 实施自主点检
Main Activities 主要活动Establish daily check list of cleaning and inspection based on standards.
依据清扫及点检标准，作成每日查核表Strictly adhere to implement daily cleaning and inspection. 严格地遵行每日自主清扫及点检Strive to achieve the goal of zero rate of breakdown.
努力追求零故障为目标Take corrective action immediately if necessary
必要时能立即采取改善措施
Total Productive Maintenance 全员生产保全 Step 5 of User’s Maintenance (2/2) 自主保全第五步骤 (2/2)
Implement inspection by user 实施自主点检
Purpose 目的 Learn the effects of equipment condition to the process capacity and quality level.
学习设备的状况对制程能力及质量水平的影响Learn the importance of adhering to Standard Operation Procedure and its effect to quality level.
学习遵守作业标准书对质量影响的重要性Review quality assurance capability of equipment.
检讨设备的质量保证能力Try to improve the process capability of equipment.
设法提升设备的工程能力
Total Productive Maintenance 全员生产保全 Step 6 of User’s Maintenance (1/2) 自主保全第六步骤 (1/2)
Implement quality assurance 实施质量保证
Main Activities 主要活动Enhance the awareness of “ 3 NO Principles of quality assurance ”
强化质量三不原则的认知 * No accept defects 不接受不良品 * No produce defects 不制造不良品 * No deliver defects 不流出不良品
Establish visual management tools for quality assurance. 建立质量保证的目视管理工具 * Visual signal board of quality rate 不良率信号牌 * Operation key points for quality assurance 质量保证的重点书 * Human error list 人为疏忽表
Strive to achieve the goal of zero defect rate. 努力追求零不良的目标
Total Productive Maintenance 全员生产保全 Step 6 of User’s Maintenance (2/2) 自主保全第六步骤 (2/2)
Implement quality assurance 实施质量保证
Purpose 目的Continue to maintain the standards
持续遵循标准工作Continue to expose problem and Kaizen
持续发觉问题并改善之Strive to achieve the goal of zero accident rate
努力追求零灾害为目标
Total Productive Maintenance 全员生产保全 Step 7 of User’s Maintenance (1/2) 自主保全第七步骤 (1/2)
Maintain Standards and Continue Improvement 自 主 维 持 管 理 及 提 升 水 准
Main Activities 主要活动Continue small group Kaizen activities
持续进行小集团改善活动Transfer more Kaizen experience to other small groups
传承改善经验予其它小团队Follow Kaizen cycle of “ Plan-Do-Check-Action ”
遵行改善循环四大阶段 “ 计划 - 执行 - 查核 - 处置 ”Get into the habit of adhering standards
养成遵守标准之习惯Use the activity display board to promote 利用展示板来倡导
Total Productive Maintenance 全员生产保全 Step 7 of User’s Maintenance (2/2) 自主保全第七步骤 (2/2)
Maintain Standards and Continue Improvement 自 主 维 持 管 理 及 提 升 水 准