TPM is put forward on the basis of American production and maintenance system, and it also absorbs the idea of mass participation in management in the articles of association of Taylor Science and Technology and China Angang. In non-Japanese countries, due to different national conditions, the understanding of TPM is to use production and maintenance activities including operators to improve the overall performance of equipment.
2、TPEM:
Total production equipment management is total production equipment management. This is a new maintenance concept, developed by the International TPM Association. This is based on the characteristics of non-Japanese culture. This makes it easier to install TPM in the factory. Unlike Japanese TPM, which is more flexible, that is to say, you can decide the content of TPM according to the actual demand of factory equipment, which can also be said to be a dynamic method. TPM is characterized by three "all", namely, full efficiency, full system and full participation.
Total efficiency: refers to the life cycle cost evaluation of equipment and the comprehensive efficiency of equipment.
System-wide: This means that all production methods and maintenance systems should be included. That is, PM, MP, CM, BM, etc. Should be included.
Full participation: refers to the participation of all departments such as equipment planning, use and maintenance, especially the independent group activities of operators. The primary purpose of TPM is to prevent and eliminate six major losses caused by equipment failure in advance: preparation adjustment, instrument adjustment, accelerated aging, inspection shutdown, 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. 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. 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. 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 TPM promotion organization and promotion committee. The range can be from the company level to the workshop level, and the responsible person can be appointed at all levels, with clear responsibilities. It is best for the promotion committees of enterprises and departments to be full-time full-time institutions, and at the same time, various professional project teams can be set up to guide, train and solve the difficult problems of TPM promotion on the spot.
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.
Check the equipment status according to the inspection manual, 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 of equipment running 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. The independent activities of TPM team are best incorporated into the organizational system. Its main activities and objectives are "four noes", that is, no waste, no faults, no accidents and no work mistakes. Its main feature is full participation, which turns what a few people did before into the conscious action of all employees.
1, composition and activity mode of the group
The team is the grass-roots organization under the workshop, generally 3- 10 people. The team leader is democratically elected and holds a regular meeting once a week, about 0.5- 1 hour. The TPM meeting of the company is held twice a year to reward excellent teams. The success of TPM depends on the enthusiasm of operators. Operators who know TPM and have progressive ideas will surely succeed. First of all, operators should be clear about the important issues of promoting TPM in the basic operation policy, that is, the basic policy and target setting of TPM. Every employee should fully understand the goals that the operators want. How to make a decision on our site in order to match the hopes of operators? From the perspective of consciously setting group goals. This is the team form in TPM. Consciousness: it is the promotion under the guidance of organizational system. Combining top-down target management with ordinary field team activities is the basic thinking mode of TPM.
2. The purpose of total productive maintenance team activities
Through mutual respect and full participation, the comprehensive efficiency of the system can be realized. Completely eliminate the seven major losses that affect the equipment efficiency, make the equipment run in the best state, ensure safety, complete the production plan, stabilize and improve the quality, reduce the cost and meet the delivery results. Therefore, it can improve its performance and become a promising factory. Take the development of the enterprise and the improvement of the quality of each employee as the purpose. In TPM, this kind of thinking and action is transformed into repeated group activities, and the purpose of TPM small organization activities can be said to be the purpose of TPM.
3. Main contents of group activities
(1) Set the goals of the team according to the overall TPM plan of the enterprise.
(2) Put forward suggestions and measures to reduce downtime, and put forward personal goals.
(3) Fill in the equipment status record carefully and analyze the actual situation.
(4) Meet regularly to evaluate the completion of the objectives.
⑤ Evaluate the results and set new goals.
Group activities are focused at all stages. In the initial stage of TPM implementation, cleaning and training are the main tasks. In the medium term, maintenance and operation are the main tasks, and in the later period, group meetings, inspections and independent maintenance are the main tasks.
4. The behavioral science thought of group activities.
The goal of group activities is the same as that of the company, so we should turn the company's goal into the needs of every employee. Whether this can be done well depends mainly on management ideas.
"Authoritative" management mode only pays attention to production variables and is used to managing enterprises with "rules" and "orders". Employees are afraid of their superiors, and this management can only improve productivity in the short term. Participatory management pays more attention to people's interest, sense of accomplishment and self-motivation, and the improvement of productivity is long-term. Good management should combine "authority" with "participation" But it should be "participatory".
5.TPM group activity method
① Activities include: STEP activities, MY-Machine activities, improvement activities of sub-projects, one-point-one-lesson education, etc.
② Conduct it in a self-disciplined manner during normal working hours, without specifying another activity time, and all the team members will promote the cleaning and improve the execution of the work.
It's best to meet once a month or so, and live in a cycle of life for more than a week.
④ Carry out MY-M/C activities for individuals at least once a week (or every day) and publish them on the activity board.
⑤ In routine activities, confirm the implementation of plan comparison, discuss the next activity plan, discuss the existing problems and suggestions for improvement.
6. Evaluation of group activities
Mainly look at four aspects.
① Self-development stage: consciously ask for mastery of technology and self-confidence.
② Improvement stage: continuous improvement of work and technology, with a sense of accomplishment.
③ Problem-solving stage: goals and enterprise goals complement each other and consciously solve problems.
④ Self-management stage: Set higher goals for the team and work independently. 1. Definition of spot check system:
Spot check system is an equipment maintenance management system centered on spot check. The medical connotation of the spot check system is just like a person having a physical examination. Some inspection methods are used for early inspection, diagnosis and maintenance of equipment. Each enterprise may formulate its own spot check system according to its own actual situation.
2. "Trinity" spot check system and the concept of five-layer protective line.
"Trinity" refers to the spot check system that combines daily spot checks by post operators, regular spot checks by professional spot checks and accurate spot checks by professional and technical personnel.
The five-layer protection line is:
The first line of defense: the daily routine inspection of post operators.
The second layer of protection line: regular inspection by professional inspection personnel.
The third layer of protection line: professional and technical personnel conduct accurate spot checks.
The fourth layer of protection line: through technical diagnosis, find out the causes and countermeasures of the problem.
The fifth line of protection: precision inspection every six months or one year.
3, the characteristics of the spot check system:
The spot check system is characterized by eight "determinations"
① Designated personnel: set up part-time and full-time spot inspectors for operators.
(2) Fixed-point: Identify the fault point of the equipment, and specify the parts, items and contents of the spot check.
③ Quantification: quantitative determination of metamorphic formula.
④ Fixed period: different equipment and different equipment fault points give different spot check periods.
⑤ Calibration: Give the basis of whether each spot check part is normal.
⑥ Plan: Make operation cards and guide inspectors to operate according to the specified route.
⑦ Fixed recording: Set a fixed recording format.
⑧ Determination process: Determine the process for handling routine check operations and routine check results.
4. Requirements of spot check system
The spot check system has six requirements, as shown in the following figure:
5. Classification of routine inspection:
According to the purpose of spot check: tendency spot check and deterioration spot check.
According to the disintegration, it is divided into disintegration spot check and non-disintegration spot check.
According to the cycle and business scope: daily routine inspection, regular routine inspection and precision routine inspection. 1. Enterprise Top Management TPM Import Decision Statement
2.TPM import education and activities
3. The TPM propulsion mechanism is established.
4. Basic policies and target setting of total productive maintenance
5. Determine the overall plan for full-time productive maintenance and promotion.
6.TPM implementation activities were officially launched.
7. Implementation of Total Productive Maintenance Pillar
8. Initial equipment management
9. Equipment quality maintenance
10. Indirect departmental management of equipment
1 1. Equipment safety and environmental management
12. The completion and implementation of total productive maintenance and horizontal total productive maintenance originated from "total quality management". Total quality management is the direct result of Dr. Edward Deming's influence on Japanese industry. Shortly after World War II, Dr. Deming went to Japan to start his work. As a statistician, he was initially responsible for teaching Japanese how to use statistical analysis in their manufacturing industry. Then how to use the data results to control the product quality in the manufacturing process. The initial statistical process and its quality control principles were quickly influenced by Japanese professional ethics, forming a way of industrial survival with Japanese characteristics. This new manufacturing concept eventually formed the well-known TQM, in which the early TPM was related to equipment maintenance.
TPM is the beginning of PM production safety introduced by Denso Japan (with several companies in Tianjin) in 196 1 year. Seven years later, the company decided to involve all employees and carry out full security. After more than two years of hard work, it achieved great success, so TPM was born. When TQM requires equipment maintenance as one of the inspection elements, it seems that TQM itself is not suitable for maintenance environment. This is because preventive maintenance (PM) measures have been taken seriously for quite some time, and most factories also adopt PM. Moreover, the technology of using PM technology to make maintenance plan to keep the equipment running normally has matured. However, when it is necessary to increase or improve the output, this technology often leads to excessive maintenance of the equipment. Its guiding ideology is: "If a drop of oil can be better, then more oil should be better". In this way, improving the running speed of equipment will inevitably lead to an increase in maintenance workload.
However, in the usual maintenance process, the role of operators is rarely or never considered, and only the contents specified in the commonly used and imperfect maintenance manual are trained for maintenance personnel, and no additional knowledge is involved.
By adopting TPM, many companies quickly realize that it is not enough to meet the manufacturing needs only by planning maintenance. In order to solve this problem under the premise of following TQM principle, it is necessary to improve the original TPM technology and bring maintenance into the whole quality process. The first important stage of development: BM stage (time: before World War II to 1950).
The second important stage of development: preventive maintenance (PM) stage (time; 1950 - 1960)
The third important stage of development: PM stage (time: 1960-1970).
The fourth important development stage: TPM stage (1970 till now)