tpm全员生产维修(编辑修改稿)

tpm全员生产维修(编辑修改稿)内容摘要：

eached maturity stage. Now is the time for applying for PM award. Also think of challenging level to which you can take this movement. Organization Structure for TPM Implementation : Pillars of TPM PILLAR 1 5S : TPM starts with 5S. Problems cannot be clearly seen when the work place is unanized. Cleaning and anizing the workplace helps the team to uncover problems. Making problems visible is the first step of improvement. Japanese Term English Translation Equivalent 39。 S39。 term Seiri Organisation Sort Seiton Tidiness Systematise Seiso Cleaning Sweep Seiketsu Standardisation Standardise Shitsuke Discipline Self Discipline SEIRI Sort out : This means sorting and anizing the items as critical, important, frequently used items, useless, or items that are not need as of now. Unwanted items can be salvaged. Critical items should be kept for use nearby and items that are not be used in near future, should be stored in some place. For this step, the worth of the item should be decided based on utility and not cost. As a result of this step, the search time is reduced. Priority Frequency of Use How to use Low Less than once per year, Once per year Throw away, Store away from the workplace Average At least 2/6 months, Once per month, Once per week Store together but offline High Once Per Day Locate at the workplace SEITON Organise : The concept here is that Each items has a place, and only one place. The items should be placed back after usage at the same place. To identify items easily, name plates and colored tags has to be used. Vertical racks can be used for this purpose, and heavy items occupy the bottom position in the racks. SEISO Shine the workplace : This involves cleaning the work place free of burrs, grease, oil, waste, scrap etc. No loosely hanging wires or oil leakage from machines. SEIKETSU Standardization : Employees has to discuss together and decide on standards for keeping the work place / Machines / pathways neat and clean. This standards are implemented for whole anization and are tested / Inspected randomly. SHITSUKE Self discipline : Considering 5S as a way of life and bring about selfdiscipline among the employees of the anization. This includes wearing badges, following work procedures, punctuality, dedication to the anization etc. PILLAR 2 JISHU HOZEN ( Autonomous maintenance ) : This pillar is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activity and technical repairs. The operators are responsible for upkeep of their equipment to prevent it from deteriorating. Policy : 1. Uninterrupted operation of equipments. 2. Flexible operators to operate and maintain other equipments. 3. Eliminating the defects at source through active employee participation. 4. Stepwise implementation of JH activities. JISHU HOZEN Targets: 1. Prevent the occurrence of 1A / 1B because of JH. 2. Reduce oil consumption by 50% 3. Reduce process time by 50% 4. Increase use of JH by 50% Steps in JISHU HOZEN : 1. Preparation of employees. 2. Initial cleanup of machines. 3. Take counter measures 4. Fix tentative JH standards 5. General inspection 6. Autonomous inspection 7. Standardization and 8. Autonomous management. Each of the above mentioned steps is discussed in detail below. 1. Train the Employees : Educate the employees about TPM, Its advantages, JH advantages and Steps in JH. Educate the employees about abnormalities in equipments. 2. Initial cleanup of machines : o Supervisor and technician should discuss and set a date for implementing step1 o Arrange all items needed for cleaning o On the arranged date, employees should clean the equipment pletely with the help of maintenance department. o Dust, stains, oils and grease has to be removed. o Following are the things that has to be taken care while cleaning. They are Oil leakage, loose wires, unfastened nits and bolts and worn out parts. o After clean up problems are categorized and suitably tagged. White tags is place where problems can be solved by operators. Pink tag is placed where the aid of maintenance department is needed. o Contents of tag is transferred to a register. o Make note of area which were inaccessible. o Finally close the open parts of the machine and run the machine. 3. Counter Measures : o Inaccessible regions had to be reached easily. . If there are many screw to open a fly wheel door, hinge door can be used. Instead of opening a door for inspecting the machine, acrylic sheets can be used. o To prevent work out of machine parts necessary action must be taken. o Machine parts should be modified to prevent accumulation of dirt and dust. 4. Tentative Standard : o JH schedule has to be made and followed strictly. o Schedule should be made regarding cleaning, inspection and lubrication and it also should include details like when, what and how. 5. General Inspection : o The employees are trained in disciplines like Pneumatics, electrical, hydraulics, lubricant and coolant, drives, bolts, nuts and Safety. o This is necessary to improve the technical skills of employees and to use inspection manuals correctly. o After acquiring this new knowledge the employees should share this with others. o By acquiring this new technical knowledge, the operators are now well aware of machine parts. 6. Autonomous Inspection : o New methods of cleaning and lubricating are used. o Each employee prepares his own autonomous chart / schedule in consultation with supervisor. o Parts which have never given any problem or part which don39。 t need any inspection are removed from list permanently based on experience. o Including good quality。