1、1,向零故障、零缺陷、零事故挑战,TOTAL PRODUCTIVE MAINTENANCE (TPM),全员维修（简称 TPM）,3,TPM维修培训内容 TPM Course Content,1. Course Objectives 培训目标,2. The Six Major Machine Losses 六种主要由设备造成的损失,3. Total Productive Maintenance (TPM) Objective 全员维修（TPM）目标,4. Introduction to TPM TPM维修内容介绍,4,5. TPM Detail TPM维修细节内容,6. Maintenance
2、 Planning 维修计划,7. Problem Solving 解决问题,8. Measurement of Maintenance 维修衡量依据,维修培训内容 TPM Course Content,5,1. 培 训 目 标 COURSE OBJECTIVES,AT THE END OF THIS COURSE YOU WILL BE ABLE TO: 培训结束后，你将能够：,1. Develop and improve Maintenance Inspection Schedules 制定并完善维修检测进度表,2. Identify the Root Causes of failures
3、 确定故障的根本原因,3. Use related documents effectively 有效地应用相关文件,4. Make optimal use of the Team and Teamwork 充分发挥团队的协作精神,6,2. 六种主要由设备造成的损失 THE SIX MAJOR MACHINE LOSSES,1. Machine failures 1. 设备的故障停机 2. Set-up and adjustment time 2. 设备调整耗用时间 3. Idling and minor stoppages 3. 空转和短暂停机 4. Reduced machine speed
4、 4. 设备速度的降低 5. Quality defects and rework 5. 质量缺陷及返工 6. Start up losses 6. 设备启动损失,7,THE 6 MAJOR MACHINE LOSSES 六种主要由设备造成的损失,1. MACHINE FAILURES设备的故障停机- Complete stoppage of a machine due to wearing parts not being replaced in time or an immediate failure.由于没有及时更换易损件或突发故障， 导致一台设备完全停机- Due to poor ope
5、ration (No Work Methods and Training)由于操作不当 （无操作方法和培训） - No air, steam, electricity, refrigeration, CO2 or water to production department生产用风、蒸汽、电、制冷、CO2或水的供给出问题 - Machine failures are the largest loss of all设备停机是所有损失中最大的损失,8,THE 6 MAJOR MACHINE LOSSES 六种主要由设备造成的损失,2. SET-UP AND ADJUSTMENT TIME设备设定和
6、调整耗用时间- Bottle size change (640 ml. TO 355 ml.) 更换瓶型 (从640毫升瓶更换到355毫升瓶) - Label shape change on the labelling machine 贴标机更换不同尺寸的商标 - Change over to new BBT清酒罐倒罐- Machine change parts must be well stored and be readily available 妥善保管设备备件，备件可随时供应- Step by step change over work method must be documente
7、d and trained 逐步记录下备件更换操作步骤及对相关人员进行培训,9,THE 6 MAJOR MACHINE LOSSES 六种主要由设备造成的损失,3. IDLING AND MINOR STOPPAGES ( 2 MINUTES)空转和短暂停机（小于2 分钟）- Crowner chute jams that stop the filler压盖机瓶盖卡壳，使装酒机停机- Falling and jamming bottles on the conveyors走链上瓶子滑倒和挤塞- Badly cut labels or poor glue at the labeller贴标机所用
8、商标尺寸超标或标胶质量差- These small stoppages that occur frequently can be eliminated 这些经常发生的短暂停机频率是可以降低的,10,THE 6 MAJOR MACHINE LOSSES 六种主要由设备造成的损失,4. REDUCED MACHINE SPEEDS设备速度的降低- Filler running below rated speed装酒机低于额定速度运行 - Other machines are not running according to design speed settings其它设备没有按速度匹配图所要求的
9、速度运行- Bottle washer running with empty bottle pockets洗瓶机运行时有空的载瓶斗- The speed is reduced usually because of a problem 通常由于存在问题而导致速度下降- Less output is achieved from a slow machine 速度的降低导致产量下降,11,THE 6 MAJOR MACHINE LOSSES 六种主要由设备造成的损失,5. QUALITY DEFECTS AND REWORK质量缺陷及返工- Under filling and decant beer
10、 at the filler装酒机灌装液位不足,必须重新灌装- Too much co2 in the beer or warm beer啤酒CO2含量过高或温度过高- Leaking crowns after the pasteuriser杀菌后瓶盖漏气- Dirty bottles from the bottle washer洗瓶机出口瓶子较脏- Ineffective labelling不合格贴标- Unacceptable product must be re processed. It is time wasted. Extra product could have been pro
11、duced 不合格的产品必须返工。 否则利用浪费的时间又可以生产出新的、额外的产品。,12,THE 6 MAJOR MACHINE LOSSES 六种主要由设备造成的损失,6. START UP LOSSES 设备启动损失- The time lost from start up of the machine or the packaging line to stable production 设备或包装线启动后进入稳定生产的时间过长。 - Each operator has his/her way of starting up a machine. The best way must be
12、documented and trained. 每位操作工都有自己启动设备的方法。 必须记录下最佳操作方法并对操作工进行培训。- Raw Material losses which will includes beer and crown losses due to under filled bottles.原料损失将包括酒损和瓶盖损失由于半瓶酒的产生,13,3. TPM维修目标 TPM OBJECTIVES,1. To maximise Equipment Effectiveness and Productivity by eliminating all Machine Losses. 通过
13、降低设备损失来提高设备的效率和产量2. To create a sense of “Ownership” on the part of the Team through a Programme of Training and Involvement. 通过培训和参与的形式，营造一种“主人翁”的氛围 3. To promote Continuous Improvement through Small Group Activities involving Production, Quality and Maintenance Personnel. 通过工作小组中生产、质检和维修人员的共同努力， 达
14、到持续不断的进步,14,4. Continuously making Small Improvements to the Production Process rather than the search for a Single Large Improvement. 在生产过程中进行持续不断的小改进， 而不是只着眼于很大 的提高5. Continuously Eliminating Waste. 不断降低浪费6. Respecting Employees for their Contribution to the Improvement Process. 尊重员工在改进过程中所作的贡献 7.
15、 Improving the Production Process to Improve Product Quality and Productivity. 改进生产工艺以提高产品质量与产量,3. TPM维修目标 TPM OBJECTIVES,15,4. TPM INTRODUCTION,The TPM System TPM的维修体系,Carried out before the breakdown 故障出现前采取措施,5% of artisan time spent on breakdowns. 维修工5%的时间用在故障维修,95% of artisan time spent on Plan
16、ned Maintenance Inspections 维修工95%的时间用在计划巡检,1. The re-active way等待故障发生,2. Carried out after the breakdown故障出现后采取措施,3. 95% of artisan time spent on breakdowns 维修工95%的时间用在故障维修,4. 5% of artisan time spent on planned inspections 维修工5%的时间用在计划巡检,The Past Repair System 传统的大修体系,TPM介绍,16,4. TPM INTRODUCTION,
17、5. No focus on preventing the breakdown 重点没有放在预防故障的发生,Parts replaced when standards are reached 达到磨损标准时更换部件,6. Everything is opened up and parts replacedThere are no wear standards打开所有设备并更换备件无磨损程度标准,Focus on the root causes of breakdowns着重放在故障的根本原因上,The Past Repair System 传统的大修体系,The TPM System TPM的
18、维修体系,TPM介绍,17,全员维修 PLANNED MAINTENANCE,2. Evolution of maintenance维修的发展进程,3. The maintenance system全员维修体系,4. The TPM process全员维修操作步骤,1. Results from a SA brewery after implementing TPM 南非啤酒厂在实施全员维修后的业绩。,CONTENT 内容,5. Computerised Planned Maintenance System (CMMS) 计算机维修系统(CMMS软件),18,CONTENT 内容,6. Blo
19、ck diagram of the maintenance system维修体系流程图7. CRB spare parts storesCRB备件储存,8. Typical implementation activities实施方案（建议）9. Roles and responsibilities各类维修人员的职责范围,全员维修 PLANNED MAINTENANCE,19,1993 1994 1995 1996 1997 1998,%1009590858075706560,WEEKLY PRODUCTION RELIABILITY (CONFORMANCE TO PLAN) 周生产可靠性 (
20、满足生产计划),1993 -1998,20,% 100806040200,Feb-93,Apr-93,Jun-93,Aug-93,Oct-93,Dec-93,Feb-94,Apr-94,Jun-94,Aug-94,Oct-94,Dec-94,Feb-95,Apr-95,Jun-95,Aug-95,Oct-95,Dec-95,Feb-96,Apr-96,Jun-96,Aug-96,Oct-96,Dec-96,Feb-97,Apr-97,UNPLANNED MAINTENANCE HOURS (as % of Total Maintenance Hours) 非计划内的维修时间 （作为总维修时间的
21、百分比）,1993 -1997,21,1993 1994 1995 1996 1997 1998,2.62.42.221.81.61.41.21,MAINTENANCE. COSTS 维修费用,TOTAL PACKAGING MAINTENANCE COSTS (1998: R/Hl) 总包装线维修费用成本 (1988: ZAR/Hl),1993 - 1998,22,120100806040200,Apr 94,Jun,Aug,Oct,Feb,Apr 95,Jun,Aug,Oct,Feb,Apr 96,Jun,Aug,Oct,Feb,Apr 97,Jun,Aug,Oct,Feb,Apr 98,
22、Jun,Aug,Oct,Feb,Apr 99,Jun,Aug,Dec,Dec,Dec,Dec,Dec,1993 = 100,TOTAL PACKAGING QUALITY DEFECTS (OPQS) 1993 - 1998 包装线上的总的质量缺陷 (OPQS),23,2. EVOLUTION OF MAINTENANCE维修的发展进程,Run to failure 事后维修,Time based maintenance 定期维修,Condition based maintenance 状态维修,Design for reliability新设备的设计要更具备可靠性,Effectiveness
23、效果比较,1.,2.,3.,4.,Maintenance cost维修成本,High高,Low低,24,2.1 RUN TO FAILURE事后维修,1. Unable to predict when the breakdown will happen不能预测到故障发生的时间,2. The cost of maintenance is high维修成本高,3. Spares are not always available for the repair维修时总无备件,4. Weekly production is difficult to achieve完成周生产计划很困难,2. EVOLUT
24、ION OF MAINTENANCE维修的发展进程,25,2. EVOLUTION OF MAINTENANCE维修的发展进程,2.1 RUN TO FAILURE事后维修,5. Contributes to variable beer Quality易造成啤酒质量的波动,6. Extra artisans must be available for a breakdown必须安排额外人员准备随时排除设备故障,7. Engineering staff do not have a full understanding of the equipment工程技术人员缺乏对设备的全面了解,8. Som
25、e items can be run to failure. Examples: a light bulb and vent tube rubber某些故障允许事后维修例：灯泡和酒管胶圈,26,2. EVOLUTION OF MAINTENANCE维修的发展进程,2.2 TIME BASED MAINTENANCE定期维修,1. Worn parts replaced after a fixed time periodno specifications一段时间后定期更换磨损的部件没有磨损程度检测标准,2. Very dependent on the skills and memory of t
26、he artisans非常依赖维修工的技能和记忆,3. It will lower the cost of maintenance. It can be lowered even more定期维修可以降低维修成本，但维修成本还可以降得更低,4. More effective than “Run to Failure”定期维修比事后维修效果更好,5. Will disturb equipment that is running well易被迫终止正常运转的设备,27,2. EVOLUTION OF MAINTENANCE维修的发展进程,2.3 CONDITION BASED MAINTENANC
27、E状态维修,1. Inspect wearing parts at agreed frequencies and against standards按规定的频次及标准检查部件的磨损情况,2. Monitor the condition of the equipment during operationExamples: Vibration - Temperature - Oil condition监控设备运行期间的各种状况例：振动温度油的状况,3. Take action when the problem is at alarm level在故障发展到报警状态时采取措施,4. Ensures
28、effective use of manpower and lowers maintenance cost可以充分利用人力资源并降低维修成本,28,CONDITION MONITORING 状 态 监 控,Oil analysis 油的分析- Inspect condition of oil and metal particles in the oil检查油本身的状况及油中的金属微粒Infra red thermography 红外线温度成象- Identifies gearboxes that are running hot 确定高温运转的减速机- Identifies loose elec
29、trical connections确定松动的电线连接点,Vibration analysis 振动分析- Effective in monitoring the condition/health of rotating machinery 有效地进行设备状况/良好运转的监控,29,2. EVOLUTION OF MAINTENANCE维修的发展进程,2.3 CONDITION BASED MAINTENANCE RELIES UPON:状态维修的必要条件,1. - Inspection planning: time frequencies and tasks are carried out巡
30、检计划：频次与检查项目 （主要是通过维修人员对设备关键部件按设备巡检表进行检测，及时发现设备存在的问题，解决问题）- Availability of quality spares合格备件的库存- Maintenance planning维修计划,30,2. EVOLUTION OF MAINTENANCE维修的发展进程,2. The use of modern equipment to monitor the machines用于监控设备的先进仪器，包括：- Vibration testing equipment (SKF Marlin)振动检测仪- CMMS Software （CMMS）计
31、算机维修管理软件,3. TraininG 人员培训（不断的培训对员工进行强化，深入理解TPM的应用的内在意义，培训员工的主人翁意识）,2.3 CONDITION BASED MAINTENANCE RELIES UPON:状况维修的必要条件,31,2. EVOLUTION OF MAINTENANCE维修的发展进程,2.4 DESIGN FOR RELIABILITY新设备的设计要更具备可靠性,1. CRB Projects Department and equipment suppliers work together to design out known problemsCRB工程部与设
32、备供应商共同解决已知的设计方面的问题,2. Ensures that new equipment does not have the same faults as the previous equipment确保新购买的设备不存在与现有设备相同的缺陷,3. We form a partnership with all our equipment suppliers both at plant and design level 在设备的维修和设计上与所有设备供应商建立合作伙伴关系,32,2. EVOLUTION OF MAINTENANCE维修的发展进程,2.5 THE BEST METHOD.
33、 THIS IS CALLED TOTAL PRODUCTIVE MAINTENANCE (TPM)最佳维修方式：全员维修 (TPM),1. TPM is based on a mix of the four methodsTPM是基于四种方法的综合运用,2. TPM identifies the best maintenance method for each machineTPM维修对每台设备确定出最佳的维修方案- Run to failure items identified确定需进行事后维修的部件- Time based inspections identified确定需进行定期维修的
34、部件- Condition Monitoring based inspections identified确定需进行状态监控的部件- Design upgrade when identified or necessary确定或有必要进行设计改进的部件,33,WHAT CAN TPM DO FOR CRB?TPM维修能为CRB做哪些贡献？,1. Teaches machine operators, artisans and quality control people work together as a team in operating the plant and problem solvi
35、ng促使操作工、维修工、和质检员懂得必须相互配合，共同负责设备的正常运转及排除故障,2. Identifies the root cause of the machine breakdown and prevents the breakdown from happening again确定造成设备停机的根本原因，避免类似问题再次发生,3. Identifies exactly what spares we must hold in the store确定必须库存的备件,4. Reduce the time and money spent to carry out the big repair与
36、传统的大修相比，可以缩短时间及降低费用,3. THE MAINTENANCE SYSTEM (TPM)全员维修（TPM）体系,34,3. THE MAINTENANCE SYSTEM (TPM)全员维修（TPM）体系,WHAT CAN TPM DO FOR CRB? TPM维修能为CRB做哪些贡献？,5. Reduces downtime and increases plant availability 降低故障停机和提高设备的利用率,6. Improves product quality提高产品质量,7. Reduces total cost降低总成本,8. Reduces waste an
37、d pollution降低原材料的浪费与环境的污染,9. Extends the working life of the equipment延长设备的使用寿命,10. Increases the worker knowledge of the equipment加深员工对设备的了解,35,4. THE TPM PROCESS全员维修操作步骤,WHAT IS THE TPM PROCESS?TPM维修的操作步骤是什么？,1. Partition the machine into manageable sections划分设备的维修责任区,2. Identify the failure cause
38、 for each item in the section确定设备责任区内每一部位的各种故障原因,3. Apply each failure cause to the decision logic diagram把每个故障的根本原因套用到决策逻辑图中去进行分析,4. Develop the Maintenance Inspection Schedules编制维修检测进度表,5. Develop the spare parts requirements for each piece of equipment编制每台设备的备件需求计划,36,5. COMPUTER MAINTENANCE MANA
39、GEMENT SYSTEM (CMMS)计算机维修管理系统（CMMS软件）,WHAT CAN CMMS DO FOR CRB?计算机维修管理系统能为CRB做哪些贡献？,1. Keeps a history of each machine failure, the spares used, artisan time to maintain and how much money is spent保存每台设备的维修资料，如：停机情况、更换的备件、维修所消耗的时间以及维修费用等。,2. Helps us to predict a failure before it happens有助于我们在设备停机前
40、预测将要发生的故障,3. The CMMS software will help us to make better decisions by generating management reportsCMMS软件提供的综合管理报告， 有助于我们做出更好的决策,4. Promotes continuous improvement有助于不断改进维修工作,37,Develop TPM Maintenance Inspection Schedules for each machine 制定每台设备的维修检测进度表,Training of operators and artisans 培训操作工和维修
41、工,6. THE MAINTENANCE SYSTEM 维修体系,Improve the maintenance schedule 完善维修进度表,Weekly planning meeting 计划维修周会,Carry out the Maintenance Inspection Schedules 实施维修检测进度表,Uncompleted maintenance schedules 未完成的维修进度表,CMMSDATA BASE CMMS数据库,Establish the root cause of the breakdown (problem solving) 明确造成故障的根源 (解
42、决问题),Adjust the maintenance schedule 调整维修进度表,New Maintenance Inspection Schedules 新制定的维修进度表,Machine breakdown 设备故障,Management reports 管理报告,Re-plan scheduled work 重新规划工作进度,IMPROVED: QUALITY - PLANT OUTPUT - FINANCIAL PERFORMANCE 改善: 1.质量 2.设备性能 3.财务管理,38,8. TYPICAL IMPLEMENTATION ACTIVITIES实施方案（建 议）,
43、1. Present modern maintenance practices to senior management向高层领导介绍先进的维修方式,2. Director approval to implement the project领导层批准实施维修项目,5. Appoint and train 3 TPM facilitators for brewing, packaging and utilities to co-ordinate and facilitate the process任命3名TPM协调员分别负责酿造,包装和公用工程沟通和协调实施进程,4. Senior Manage
44、ment to select a responsible person for the TPM project高层管理应指派一名负责人来负责TPM维修工作,6. Train engineering maintenance and production staff on TPM对工程技术人员、维修人员和设备操作工进行有关TPM维修的培训,3. Train the brewery management team on the concepts of TPM对公司管理人员进行有关TPM维修体系的培训,39,7. The brewery responsible person to develop a
45、project plan with the assistance of the SAB consultant公司维修项目负责人在南非专家的协助下制定本单位的维修计划,8. TPM Facilitator and machine specialists develop the TPM logic with the assistance of the SAB consultant TPM维修协调员和设备工程师在SAB专家的协助下制定TPM的逻辑分析和维修进度表,9. Developed maintenance schedules verified by the maintenance engine
46、er设备部工程师对维修检测进度表提出修改意见,10. Train artisans and operators on the maintenance schedules and to work to the agreed standards 对维修工和操作工进行执行维修检测进度表的培训，按照规定的标准进行工作,8. TYPICAL IMPLEMENTATION ACTIVITIES实施方案（建 议）,40,8. TYPICAL IMPLEMENTATION ACTIVITIES实施方案（建 议）,11. Develop the Work Order for the brewery建立公司的工作
47、信息反馈单,12. Train artisans, operators and quality control staff on the use of the Work Order 对维护工、操作工和质检员进行使用工作信息反馈单的培训,13. Implement the use of Work Order throughout the brewery在公司范围内普遍采用工作信息反馈单,14. Institute a weekly Maintenance and Cleaning co-ordinating meeting每周召开一次协调会，讨论设备的维护和清洗工作,15. Order, install and train the necessary staff on the Computer Maintenance Management System (CMMS) 购买,安装计算机维修管理软件（CMMS）和培训软件的操作人员,
