TPM target map
Adjustment, appliance adjustment, accelerated aging, shutdown inspection, speed reduction and production defects. Realize zero failure, zero defect, zero waste and zero disaster, and realize the rationalization of cost consumption while ensuring the maximum production benefit.
The goal of TPM can be summarized as four zeros, namely, zero downtime, zero waste, zero accident and zero speed loss.
Zero downtime: refers to the unplanned equipment downtime is zero. Unplanned downtime has a great impact on production, making it difficult to distribute the whole original product and wasting resources such as idleness. The planned time should have a reasonable value. In order to meet the requirement that unplanned downtime is zero, the planned downtime value should not be high.
Zero waste: refers to zero waste caused by equipment. Perfect quality needs perfect machines. Machine is the key to ensure the quality of products, and people are the key to ensure the quality of machines.
Zero accident: refers to the zero accident in the process of equipment operation. Equipment accidents are very harmful, affecting production, and may cause personal injury. In serious cases, it may "destroy the machine and kill people".
Zero speed loss: refers to zero output loss caused by equipment deceleration. Due to poor equipment maintenance, equipment accuracy is reduced, and equipment cannot be used at high speed, which is equivalent to reducing equipment performance.
key element
Efforts should be made to implement total productive maintenance from three main aspects, namely:
1, improve work skills: both operators and equipment engineers should strive to improve their work skills. Without good work skills, full participation is empty talk.
2. Improve mental outlook: Only with a good mental outlook can a good team be formed. * * * will be promoted * * will be improved.
3, improve the operating environment: through 5S and other activities, make the operating environment good, on the one hand, can improve work interest and efficiency, on the other hand, can avoid some unnecessary equipment accidents. The site is clean and tidy, and materials and tools are placed in different categories, which can also shorten the setting adjustment time.
skill
First, create changes in the production site.
In the implementation of management strategy, if employees want to actively participate, the most critical factor is to create local changes and eliminate employees' cognitive blind spots. In other words, managers create rapid changes in the field department, so that employees can see these changes at the first time, thus enhancing their confidence in improving activities and improving work efficiency.
Secondly, guide employees to actively participate in improvement.
How to guide employees to participate in the improvement of enterprises has always been a problem worth discussing. Because it is obviously impossible for an enterprise to achieve its goal only by relying on the strength of a few managers, in this case, employees need to participate in the improvement of the enterprise, so as to play the best effect. However, how to guide employees? In fact, if employees want to participate in the promotion, they need to feel the development momentum of the enterprise and feel their value in the enterprise. If employees can't see the development prospect in the enterprise, or their own value can't be reflected in the enterprise, then they are unlikely to improve with the enterprise. Therefore, enterprises should encourage employees and give them enough trust, so as to stimulate their enthusiasm and let them join the ranks of improvement.
Finally, enterprises should constantly set higher goals.
In order to clarify the effect of TPM activities, enterprises should master the principle of step by step. However, in reality, some enterprises often make the mistake that if they set their goals high from the beginning, employees will not only feel out of reach, but also lose their confidence and motivation to improve, and eventually the improvement activities of enterprises will end in failure. In fact, the most scientific method is to constantly set higher goals, and the process of continuous improvement needs to be gradual. Enterprises should put forward different goals at appropriate times according to the implementation of improvement, and gradually improve the level of goals, thus improving efficiency.
execution step
Developing TPM is not an easy task, and it needs the strong support of all parties, especially the leaders of the factory. The specific development process can be divided into three stages, and the specific steps are 10.
TPM development process stage
First, the preparation stage.
1.TPM introduction publicity and personnel training are carried out at different levels.
2. Establish TPM promotion agencies and establish TPM promotion committees and professional organizations at all levels.
3. Formulate the basic principles and objectives of total productive maintenance, put forward benchmarks and set target results.
4. Make the overall plan for TPM promotion.
Second, the introduction and implementation stage
5. Formulate measures to improve the comprehensive efficiency of equipment, select equipment and replace it with the assistance of professional guidance group.
6. Establish independent maintenance procedures
7. Make a maintenance plan
8. Training to improve operation and maintenance skills
9. Establish management procedures for initial equipment.
Third, the consolidation stage.
10. Summarize and improve, fully implement TPM summary and evaluation, find the gap and set higher goals.
This stage is mainly to make TPM plan and create a suitable environment and atmosphere. You can perform the following four steps. 1, preparation stage
①TPM introduction and personnel training are mainly to publicize the benefits of TPM and the benefits it can create for employees, educate employees to establish the concept of unity, and break the thinking habit that "operators only care about operation and maintenance workers only care about maintenance".
② Establish an organization to promote TPM? The establishment of the Promotion Committee can designate the person in charge from the company level to the workshop level and give them powers and responsibilities. It is best for the promotion committees of enterprises and departments to be full-time full-time organizations, and at the same time, various professional project teams can be set up to guide and train TPM implementation and solve the problems in on-site promotion.
③ Establish the basic total productive maintenance strategy and objectives.
The goal of TPM is mainly manifested in three aspects:
A. What is the purpose?
B.how much (how much)
C. Timetable (when)
That is to say, when to reach what level on those indicators, the order of considering problems can be carried out in the following ways: external requirements → internal problems → basic strategies → target scope and overall goals.
(4) Establish the overall plan for TPM promotion.
Do a good job in overall planning and put forward slogans to effectively implement TPM. Step by step towards the overall goal of four "zeros".
The main contents of the plan are embodied in the following five aspects.
Answer: Improve the comprehensive efficiency of equipment;
B: Establish independent maintenance procedures for operators;
C: quality assurance;
D: working schedule of maintenance department;
E: Education and training, awareness-raising and skills-raising
The above contents can be made into a table, as follows:
2. Introduction to the implementation stage
This stage is mainly to set goals, implement various measures and carry out work step by step.
① Formulate measures to improve the comprehensive efficiency of equipment.
Establish a professional project team, including equipment engineers, operators and maintenance personnel. The project team selects different kinds of key equipment in a planned way, grasps typical cases, summarizes experience, and plays a role from point to area.
The project team should help the grass-roots operation teams to determine the equipment inspection and lubrication parts cleaning, solve the maintenance difficulties, and improve the confidence of operators in independent maintenance.
② Establish an independent maintenance program.
First of all, we should overcome the traditional concept of "I operate, you maintain" and help operators establish the confidence and thought of "operators maintain independently and everyone is responsible for the equipment".
Carry out 5S activities, and on the basis of 5S, carry out "seven steps" of self-maintenance.
Self-maintenance "seven steps"
Step name is internal content.
1 Initial cleaning, dust cleaning, good lubrication and screw fastening.
2 formulate countermeasures to prevent dust and sludge pollution, improve the situation of difficult-to-clean parts and reduce the difficulty of cleaning.
3. Establish equipment cleaning and lubrication standards one by one, and establish reasonable cleaning and lubrication standards one by one.
4 according to the inspection hand for inspection.
Check the equipment status, and the team leader will guide the team members to carry out various inspection items.
5 Self-inspection Establish the self-inspection standard, conduct inspection according to the self-inspection table, and refer to the inspection table of the maintenance department to improve the self-inspection standard of the team. Set new targets and maintenance departments to determine the boundaries of different inspection categories and avoid overlapping and unclear responsibilities.
6. Organize and rectify the standards of various workplaces, such as cleaning and lubrication standards, site cleaning standards, data recording standards, tools and parts maintenance standards, etc.
Automatic independent maintenance workers can carry out independent maintenance consciously and skillfully, with strong self-confidence and a sense of accomplishment.
③ Make a maintenance plan.
Maintenance plan refers to the daily maintenance plan of the maintenance department and should be combined with the independent maintenance activities of the Group. Study and adjust the maintenance plan according to the development of the team. It is best for the production manager to have a meeting with the equipment section chief once a day to solve the problems in production and arrange and adjust the maintenance plan at any time.
④ Training to improve operation and maintenance skills.
Training is an investment with multiple returns. It is necessary to train not only the maintenance skills of operators, but also their operation skills. Training should suit the remedy to the case, teach students in accordance with their aptitude and conduct training at different levels.
Training object training content
The section chief trains management skills and basic design modification techniques.
Experienced worker training and maintenance application technology
Senior operators learn basic maintenance skills, fault diagnosis and maintenance.
Beginners and new workers learn basic operation skills.
⑤ Establish the initial management program of equipment.
Many problems in the operation of equipment with load are often hidden in the stages of equipment design, R&D and manufacturing, manufacturing, installation and trial operation. Therefore, maintenance prevention and maintenance-free design should be considered in the early management of equipment. In the stages of equipment selection (or design and development), installation, debugging and trial operation, the equipment should be improved according to the test results and problems. The specific objectives are:
(1) Strive to reach the highest level within the scope of equipment investment planning.
② Reduce the cycle from design to stable operation.
③ The workload is small.
④ Ensure that the design reaches the highest level in terms of reliability, maintainability, economic operation and safety.
3. Consolidation stage
This stage is mainly to check and evaluate the results of total productive maintenance. Improve the shortcomings and set higher goals for the next step. Create greater benefits for enterprises.