??????EMBA-6 ??????(TPM)

1
??????EMBA-6
??????(TPM)

• ??????? ??
• ????????
• ?????????????
• ???????
• 20041219

2
??????

• ??
• ?????,??????????????????????????????
• ???????????,????????????????????????????
• ???????,???????????????,???????????

3
TPM??

• Total Productive Maintenance
• Total Productive Management
• Total Perfect Manufacturing

4
Total productive maintenace what does it mean?

• Total Everyone
• Productive No wasted activity
• Maintenace As new condition

5
TPM???

• ????????(?????)??????
• ???????????????,????????????????????,???0?????0???
  ??0????
• ???????,???????????????
• ??????????????????

6
TPM???

• Preventive Maintenance
• 50????????Preventive Maintenance(????,??PvM),???50
  ?????Break-Down Maintenance(????,??BM)?????,??????
  ????????
• ???????,???????,????????,????????????
• ????(????????????????),????,????,????,?????

7
TPM???

• Productive Maintenance
• 60???Productive Maintenance(????,??PM),???????????
  ?,?????????
• ????????,?????????
• ????
• ????????????
• ???????????

8
TPM???

• 70???Total Productive Maintenance(??????,??TPM),??
  ??????????????,?????????????????????????
• 80????Predictive Maintenance(????,??PdM),?????????
  ????,???????????,??????????,??????????????????????
  ??(Over Maintenance)?

9
TPM???

• Total Productive Management
• 90??JIPM???????????TPM????,?????????????????,??TPM
  ????,?????TPM?
• 91????????????TPM????,?23???700????,??VOLVO?????NA
  CHI INDUSTRIES PTE.LTD.??????????TPM????2????
• 1999?????????????????????,???????????????????????,
  ???????TPM?????????

10
TPM???????
?? ??????
??????
?????? ??????? ??????
???????? ?????? ??????
???? ???????
???????
???? ???????
???????
???? ???
????????
11
??TPM?????

• ?80????,???TPM????????????????????????????????????
  ???????????????????,????????????

12
TPM?8???

• ??????
• ????
• ????
• ????
• ???????????
• ????
• ??????????
• ??????????

13
TPM?8???

• ??????
• ????????????,????????,???????
• ????????
• ????????????,????????,??????,???????????
• ?????????,???????

14
TPM?8???

• ????
• ?????????vs????????,???????
• ??????
• ????
• ????

15
TPM?8???

• ????
• ????
• ????
• ????
• ????
• ?????,?????????????,??????????????,????????,??????
  ?,??????,?????????

16
TPM?8???

• ????
• ????????????
• ???????????,?????????

17
TPM?8???

• ???????????
• ?????????
• ?????????(Design Review)
• ??????80?????,???????????,??80?????
• ???????

18
TPM?8???

• ????
• ???????,????????????
• ???????
• 4M(Machine?Material?Method?Man)
• ???
• ???????
• ???,??????????

19
TPM?8???

• ??????????
• ???????????????????
• ??????????
• ????????
• ??????

20
TPM?8???

• ??????????
• ??3K(????????),??????????????????
• ??????(False Alarm)??

21
OEE?TPM???????

• Overall Equipment Effectiveness(??????,???OEE)
• ?JIPM????TPM?,???????????????

22
??OEE

• Machine Availability (Scheduled Running Time -
  Downtime)/ Scheduled Running
• Performance Rate (Std. Cycle Time /Act. Cycle
  Time) X (Act. Cycle Time X Units Produced/ Time
  Available Operating Time)
• Quality Rate (Units Produced - Defective
  Units)/ Units Produced
• OEE Availability X Performance Rate X Quality
  Rate

23
OEE

• Availability is reduced by
• Shutdowns
• Breakdowns
• Changeover times
• Lack of skilled operators

24
OEE

• Performance rate is reduced by
• Failure to operate at the maximum proven rate
  (MPR) or original equipment manufacturers
  specifications (OEMs)
• Minor stoppages
• Idling

25
OEE

• Quality is reduced by
• Producing waste
• Defects
• Rework
• Start up losses

26
Average OEEs vs World Class OEEs myths and
realities
27
World class OEE

• UK best about 40-50
• World class generally accepted as
• For single product process plant gt 95
• For batch plant gt 85

28
OEE???

• ????????????
• ???????????????????
• ???????????
• ???????
• ?????????

29
TPM?5S????

• 5S???TPM?????????
• ???????,????5S?????????TPM?????

30
5S(visible factory)

• ?5S???????,????????????????
• ?5S?????????????,?????????5S???????????????

31
The 5Ss

• In Japanese
• 1st S ??(Seiri) Sort
• 2nd S ??(Seiton) Set in order (stabilize)
  
• 3rd S ??(Seiso) Shine
• 4th S ??(Seiketsu) Standardise
• 5th S ??(Shitsuke) Sustain

32
?5S???? ????-9309????(?)251?
?? ???? ?? ???? ????
? ? 20? 1.??????????? 5
? ? 20? 2.??????????? 4
? ? 20? 3.??????????????? 4
? ? 20? 4.???????????????? 4
? ? 20? 5.??????????????? 3
? ? 20? 1.??????????????? 3
? ? 20? 2.???????????????? 3
? ? 20? 3.???????????????? 4
? ? 20? 4.?????,?????????? 3
? ? 20? 5.???????????? 4
? ? 20? 6.??????????????? 3
33
?5S???? ????-9309????(?)252?
?? ???? ?? ???? ????
?? 20? 1.???????????????? 5
?? 20? 2.???????????????? 4
?? 20? 3.????????????? 4
?? 20? 4.??????????????? 4
?? 20? 5.??????????????? 3
?? 20? 1.3S?????,?????? 4
?? 20? 2.????????????? 4
?? 20? 3.???????,?????? 4
?? 20? 4.?????????? 4
?? 20? 5.???????????????? 4
?? 20?
34
?5S???? ????-9309????(?)252
?
?? ???? ?? ???? ????
? ? 20? 1,?????????????? 4
? ? 20? 2.??????????,???? 4
? ? 20? 3.?????????? 4
? ? 20? 4.????????????,???????? 4
? ? 20? 5.??????????? 4
??



35
TPM????

• ??????
• ?????TPM??????
• TPM?????????
• TPM???????????
• TPM???????????
• TPM??????
• ????
• TPM?????(Kick-Off??)

36
TPM????

• ???????
• ???????????
• ????
• ????
• ????
• ????
• ???????????
• ????????
• ??????????????
• ???????????????

37
TPM????

• ????
• TPM???????????
• ???????TPM???

38
???????

• ?????
• ???????
• ?????,?5S
• ????autonomous and preventive maintenance
• ???????(Kaizen)????????
• ??????,?SMED(Single Minute Exchange of Dies)

39
???TPM???????????
?? ??
??
P (??) ???????
??? 1.52?
??????
??? 1.52?
??????
??? 1/101/250
Q (??) ??????
??? 1/10
??????
??? 1/4
C (??) ????
??   30
D (???) ????
??   50
S (??) ????0,??0
????0,??0
M (??) ?????? 
??   510
40
TPM?????

• ???????
• ???????
• ???????
• ?????????????????
• ?????????????

41
??
42
SMED

• Single minute exchange of dies
• By Shigeo Shingo
• The approach to reduce output and quality losses
  due to changeover