Total Productive Maintenance (TPM) Duy tri nng sut tng th
Huynh Bao Tun 0903786898 [email protected]
Mt s trao i-
Nng sutCn thay i quan im v nng sut truyn thng: san phm/gi, san phm/cng lao ng/n vi thi gian nng sut lao ng tng nng sut, giam cht lng. Nng sut: hiu qua va hiu sutHiu qua: do the right thing, la ung vic Hiu sut: do the thing right, lam mt vic gi o mt cach ung Tng nng sut la tng cht lng, tng hiu qua kinh doanh, tng s thoa man khach hang. S ti u hoa ngun lc
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Quan lyMt nhom ngi cung nhau at n mt muc tiu cu th, trong mt gii han v ngun lc. Quan ly la noi v con ngi (muc tiu ca nhn, hanh vi, vn hoa, ca tinh..), lam sao cho tp hp nhng ngi khac nhau cung nhau hoan thanh nhim vu kho khn, phc tap. Quan ly s thay i2
Gii thiu TPM
Total Productive Maintenance (TPM) la gi:Mt trit ly v quan tri vn hanh cn thm su vao tng ca nhn moi cp La tp hp cac cng cu thc hanh ti u hoa hiu qua c s vt cht va quy trinh kinh doanh
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y la cach tip cn cua ngi Nht : Tao ra vn hoa doanh nghip hng ti hiu qua cao nht. Phn u ngn chn thit hai, ti thiu chi phi Khng s c, khng li, khng tai nan, khng khuyt tt
S cn thit cua hoat ng theo nhom (nhom nho) tp trung vao s cai tin iu kin va hiu qua cua c s vt cht hng ti muc tiu tn tht bng khng (KAIZEN) Lin quan n tt ca moi ngi t cp lanh ao cao nht n cp tht nht
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Tac ng bng chinh sachQua trinh tac ng Tac ng muc tiu ca nhn cung hng Muc tiu cua t chc vi muc tiu t chc Thay i mt cach linh hoat cho nhng muc tiu ca nhn va muc tiu t chc
Muc tiu ca nhn cua tng nhn vin
Thay i t nhng yu t khng th kim soat t bn ngoai
Lich s/ngun gc TPM c gii thiu tai Nht cach y 20 nm va ang c ap dung manh me TPM c h tr trin khai bi t chc JIPM (Japan Institute of Plant Maintenance) Trao tng cac giai thng hng nm cho cac linh vc: t Luyn kim Hoa cht Cao du Thc phm Thuy tinh 6
c ng dung u tin trong nhng linh vc san xut vi san lng ln Sau o c nghin cu trin khai: San xut san lng thp Lp rap san lng thp Kho bai Va toan nganh cng nghip
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Vai tro cua TPMNhng cu hoi thng gpTPM thay th cac th cac phng phap bao tri truyn thng nh th nao ?
Tai sao no lai ph bin va quan trong ? Nhng chinh sach va muc tiu cua no la gi? Cac bc thc hin, cac hoat ng cac thanh phn cu thanh TPM la gi: o lng kt qua va li ich ma TPM mang lai?
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TPM va ky thut bao tri truyn thng Bao tri theo kiu phan ng se mang lai nhiu lang phi va kem hiu qua, cu th: Khng canh bao c nhng kha nng gy li Rui ro v an toan cao Thi gian dng may khng theo k hoach cao Tn tht trong san xut ln
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Bao tri theo kiu phan ng cn co May moc thi gian ch i ngu bao tri trong thi gian ch Tn kho phu tung
Chi phi Kim tra trc khi san xut Pha v k hoach Sa cha May moc dang ch Phu tung10
Chi phi thc cho vic bao tri theo kiu phan ng ln hn rt nhiu so vi ngun lc, vt t bo ra cho vic bao tri Bao tri theo kiu chu ng (lp k hoach, ngn nga, d bao) c mong mun giam chi phi.
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TPM cho phep hoc cung cp: S thay i t bao tri ng pho sang bao tri chu ng Mt c ch Cac s c c phn tich mt cach thu ao Tim kim trit cac nguyn nhn Mt k hoach hanh ng cu th ngn nga s c trong tng lai Lich bao tri ngn nga c thc hin vi nhiu y nghia hn12
co c s thanh thi nhng chuyn nghip trong bao tri: Thc hin bao tri theo lich trinh va d phong Thu thp thng tin lin quan nh la mt u vao quan trong trong h thng bao tri Gi cho h thng lun c cp nht Ra soat hiu qua v chi phi phat trin va vn hanh mt h thng bao tr rt co hiu qua, mt phn cua san xut
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Tai sao TPM quan trong va ph bin?Co 03 ly do 1. No am bao mt kt qua thuyt phuc (Kt qua hu hinh, o lng c) Giam thi gian h hong thit bi Giam thiu thi gian nhan ri va dng nho Giam san phm khuyt tt va nhng khiu nai Tng nng sut Giam nhn cng va chi phi Tn kho thp hn Giam tai nan14
2. Thay i ro rt ni lam vic (mi trng nha may)Thng qua TPM, mt nh my bn thiu bi du m, cht long ro ri v bt co th thay i thanh mt mi trng lam vic d chiu va an ton Khach hang va khach tham quan n tng manh me v nhng thay i nay. T tin vao s tng trng san phm cua nha may
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3. Nng cao trinh , ky nng va kin thc cho ngi lao ngKhi hoat ng TPM bt u tao ra c nhng li ich, no se giup: Tao ng lc cho ngi lao ng Tng cng s lin quan (chia se, lam vic nhom, trach nhim) Tng cng s sinh si nay n cua cac xut (tao mm y tng). Moi ngi bt u thy TPM la mt phn trong cng vic.16
Chinh sach va muc tiu cua TPM Ti u hoa hiu qua tng th thit bi (khng s c, khng sai li, khng tai nan, khng khuyt tt) thng qua s tham gia cua tt ca moi ngi. Nng cao s tin cy cua may moc thit bi va nng lc bao tri ong gop cho cht lng va nng cao nng sut17
Chinh sach va muc tiu cua TPM Cc ai li ich kinh t cua trang thit bi trau di chuyn mn lin quan n thit bi v k nng gia cac chuyn vin vn hanh tao ra mt mi trng lam vic manh me v nhit tinh18
12 bc phat trin chng trinh TPMGiai oan chun bi1. Chinh thc cng b quyt inh gii thiu TPM2. Gii thiu nhng khai nim c ban va li ich cua TPM 3. Truyn thng tao s thu hut v TPM trong toan t chc19
Giai oan chun bi (tt) 4. Thit lp nhng chinh sach va muc tiu cua TPM 5. Phat thao mt k hoach tng th cho vic trin khai TPM Giai oan chun bi 6. Khi ng nhng sang kin cho TPM(tao khng kh nng cao tinh thn, cam hng va s cng hin)20
Trin khai7. Xy dng mt chinh sach (lut l) cho toan cng ty trong vic ti u hoa hiu qua s dung c s vt cht.i. Tin hanh tp trung hoat ng cai tin ii. Thit lp va trin khai chng trinh t bao tri. iii. Trin khai k hoach chng trinh t bao tri iv. ao tao hng dn ky nng vn hanh va bao tri
8. Xy dng mt h thng quan l sm cho san phm mi va thit bi21
Trin khai (tt.)9. Xy dng mt h thng bao tri cht lng
10. Xy dng mt h thng quan tri va h tr hiu qua 11. Phat trin mt h thng quan ly sc khoe, an toan va mi trng
Hp nht12. Duy tri vic trin khai TPM mt cach bn vng va nng dn cp (giai thng)22
5 hoat ng nn tang cua TPM1. T Bao tri - Autonomous maintenance 2. Cai tin trang thit bi - Equipment improvement 3. Bao tri cht lng - Quality maintenance 4. Xy dng h thng bao tri ngn nga (Prevention Maintenance) 5. ao tao23
Hoat ng cua TPM T bao tri
Muc tiuLoai bo sau tn tht ln thng qua hoat ng cai tin cua cac nhom nho. Ngi vn hanh may phai bit t bao tri, t chiu trach nhim mi thit bi minh vn hanh
B phn San xut
Cp Vn hanh
Cai tin trang thit bi
Cc ai hiu qua s dung tng th trang thit bi hin co (OEE - Overall Equipment Effectiveness) Cai tin tng th phng phap vn hanh cc ai OEEam bao 100% san phm khng bi khuyt tt, h hong (co nguyn nhn t bao tri) Tao ra mt h thng am bao rng thng tin v k thut a at c thng qua hoat ng TPM trong ni b c phan anh trong cc thit k cua cng cu theo may bn bn ngoi cng ty -am bao ngi vn hanh may thit bi co u kin thc va ky nng lam vic. -M rng ao tao ky nng cn thit t bao tri thit bi
San xut
Quan ly
Bao tri cht lng Bao tri ngn nga
San xut K thut
Quan ly va vn hanh K s
ao tao
Bao tri
Quan ly24
Cp TPM
Cp 1 - Xac inh nhanh nhng vic cn loai bo Phi bay va chinh sa nhng bt thng cua thit bi 1. 2. Tin hanh lam sach ban u Tim ra nhng nguyn nhn lam cho thit bi bi d bn Cai tin nhng khu vc kho lam sach
Cp 2 loai bo nhng h hong Hiu ro chc nng va cu truc cua thit bi 4. Chun hoa hoat ng bao tri. Phat trin cac k nng giam sat tng quat
Cp 3: Loai bo khuyt tt Hiu mi quan h gia thit bi va cht lng 6. Tin hanh t giam sat. 7. T chc va quan ly ni lam vic
Cp 4: Tao ra li nhun
Nhn vin vn hanh t bao tri
Tao iu kin thc hin t bao tri
Cac bc
8. Quan ly mt cach t ng
3.
Cai tin thit bi
Loai bo nhng tn tht man tinh do nut tht c chai trong qua trinh san xut gy ra
Duy tri khuyt tt bng khng sau khi cai tin
Thit lp nhng iu kin chun khng co khuyt tt
Lam cho thit bi at hiu sut cao hn
Bao tri cht lngXy dng h thng bao tri ngn nga ao tao
100% san phm co cht lnghp tac vi nha san xut trao i thng tin v cac hoat ng TPM i vi thit bi va cng cu mi Thng xuyn ao tao cng nhn co nhng kin thc va k nng v thit bi 25
Hi phuc, bao tri, nng cp nhng trang thit bi sn co Mua va lp t thit bi mi mang lai hiu qua cao nht Xy dng va giam sat hiu qua cac qua trinh cai tin
Phat hin va loai bo nhng li co sn cua thit bi
Tt ca cung tham gia
Thit lp va duy tri mt ni lam vic sach se, gon gang, ngn np
Cung cp va cai tin h thng bao tri
Phat hin va loai bo tt ca cac h hong
Thc hanh TPM26
Thc hanh TPM Phuc
hi, bao tri, va cai tin c s vt cht sn co
Vai tro cua cng nhno tin hanh sa cha
Vai tro cua ngi quan lyo duy tri nhng iu kin c ban ngn chn suy giam27
Vai tro cua cng nhn (tt) o cai tin nhng im yu va loai tr s suy giam o lp k hoach bao tri ngn nga oPhn tich nhng h hong va tinh nng, thc hin vic bao tri tin oan
Vai tro cua quan ly (tt) o Giam sat hiu qua may moc thit bi o thng xuyn giam sat nhng vn h hong, khuyt tt
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Phat hin va loai tr s h hongH hong: o gy ra s dng may t ngt o lam chm quy trinh san xut
o lam chm qua trinh vn hanh va lam moi th kho khn hn o lam cho vic chuyn i kho khn hno lam cho ni lam vic d bn o lam cho vic vn hanh va sa cha may tht ang s tai nan29
o lam cho moi th khng nht quano gy ra s loai bo
o lam tng s nguy him
Xy dng, giam sat va cai tin hiu qua cua quy trinhNhn dang, o lng va giam 6 tn tht ln (six big losses) sau: 1. Tn tht do dng may t ngt 2. Tn tht do khi ng va hiu chinh 1 va 2 = tn tht thng gp30
Sau tn tht ln (tt.): 3. 4. 5. 6. Chay khng tai v thit hai do ngng nho Tn tht do giam tc Tn tht do ph liu va lam lai Tn tht khng phat hin khi n tay ngi tiu dung (hinh anh, thng hiu)
3 va 4 = tn tht n hiu qua vn hanh 5 va 6 = tn tht cht lng31
Thit lp va duy tri h thng lam vic ngn np, sach se gon gang5 Japanese Ss 1. Seiso2. 3. 4. 5. Seiri Seiton Shitsuke Seiketsu
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Phat hin va loai tr nhng li co sn cua thit bi: Phat hin nhng li tao ra trong qua trinh thit k va san xut thit bi c phat hin trong qua trinh vn hanh
C gng loai bo tt ca nhng anh hng nay khi co th.33
Phat hin va loai tr nhng li co sn cua thit bi (tt.) - xut mt d an vi mt nhom nho co nhng ky nng tt tt trung vao cac li co sn cua thit bi nng cao hiu qua tng th cua thit bi bao gm Cai tin nhng cai sn co Giam thi gian chuyn i va khi ng Tng cng tin cy34
Cai tin tinh nng hoat ng Phn tich nhng tn tht kinh nin va cai tin Cai tin quy trinh Cai tin vn hanh
Cai tin cht lng Nghin cu nng lc qua trinh va cai tin Trit ly Poka yoke Tai thit k at c s n inh cua qua trinh vn hanh35
Cung cp va cai tin h thng bao tri Gii thiu nhiu cng cu va ky thut chuyn nghip xy dng va phuc hi tinh trang may moc H thng bao tri va ngun c xy dng, trin khai va lin tuc cai tin. Tng cng ky nng chuyn mn cho cac ky s thc hin vic cai tin nhng vn phc tap.36
Mua va lp t thit bi mi mang lai hiu qua cao nhtVic la chon va mua thit bi mi cn tip cn theo: cach chuyn nghip va co cu truc Tich hp c vi cac h thng san xut hin hanh
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Vic la chon va mua thit bi mi cn tip cn theo (tt): Phu hp vi trit ly TPM cua cng ty ap ng yu cu san xut kinh doanh hin tai va tng lai Nhm n kha nng canh tranh tm toan cu
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o lng hiu qua cua c s vt cht, trang thit bi (facilities)Hiu qua cua facilities Li ich tng th cua no tao ra
Overall Equipment (facilities) effectiveness (OEE) hiu sut tng th trang thit bi =%Availability Tn tht do dng may t ngt Tn tht do khi ng va hiu chinhThi gian thit bi co th hoat ng ti a
x
%Performance x Chay khng tai v thit hai do ngng nho Tn tht do giam tc San lng thc so vi san lng thit k
%Quality Tn tht do ph liu va lam lai Tn tht khng phat hin khi n tay ngi tiu dung (hinh anh, thng 39 hiu)
Thi gian chay may dng may, sa cha (t xut) %Availability = -----------------------------------------------x 100 Thi gian chay may Thi gian chay may = Thi gian vn hanh theo k hoach nghi ngi bao dng theo k hoach S san phm san xut c = ----------------------------------- x 100 Thi gian chay may x san phm/vi thi gian
% Performance hoc
Thi gian chay may dng san xut nho giam tc = -------------------------------------------------------------- x 100 thi gian chay may40
% Quality = Tng s san phm san xut khuyt tt lam lai ---------------------------------------------------------------------x 100 Tng s san phm san xut
hocThi gian chay may thi gian sa cha khuyt tt = -------------------------------------------------------------- x 100 Thi gian chay may
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VD 1 Mt cng ty san xut nho, + cng sut ly thuyt la 2 san phm/phut. + S lng san phm san xut c 800, thi gian san xut la 2 ca, 8 h/ca. + Thi gian nghi va bao dng theo k hoach 40 phut + Thi gian h may 40 phut, thi gian chuyn i va hiu chinh 1h 20 p. + S lng san phm bi loai va lam lai la 10 va 6 Tinh hiu sut tng th trang thit bi OEEThi gian san xut theo k hoach = 2x8 h. = 960 phut Thi gian chay may= 960-40 (nghi, bao dng theo lich) = 920 phut. Thi gian dng may=40 (may h) + 80 (chuyn i, hiu chinh)= 120 Chay may Dng may 920 - 120 %Availability = --------------------------------x100 = ----------------x100 = 87% Chay may 920
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VD 1 (tt.)San phm san xut c 800 %Performance = --------------------------------x100 = -------------x100 = 50% thi gian chay may x cng sut (920-120)x2
Tng s san phm san xut khuyt tt lam lai %Quality = ----------------------------------------------------------------------- x 100 Tng s san phm san xut 800 10 6 = -------------------- x 100 = 98% 800 Overall effectiveness (OEE) = 0.87 x 0.5 x 0.98 x 100 = 42.6 %43
VD 2 mt nha may hoa cht ky vong chay lin tuc 120 h/tun vi cng sut la 2400 tn/h. kt thuc tun ho san sut c 220,000 tn va 3000 tn ph phm. Ho co 120p dng may do h hong va 460 p chuyn i va hiu chinh. Tinh OEEThi gian san xut theo k hoach= 120 h/tun = 7200 phut San xut lin tuc, nghi bao dng theo lich= 0 Thi gian chay may = 7200-0 = 7200 phut. Thi gian dng may = 120 (h hong) + 460(chuyn i va hiu chinh) = 580 Chay may dng may 7200 - 580 %Availability = --------------------------------x100 = ----------------x100 = 92% Chay may 720044
VD 2 (tt.)san lng 220,000 %Performance = ---------------------------x100 = ------------------x100 = 83% Thi gian chay may x cng sut (6620)x(2400/60)
san lng ph phm %Quality = ---------------------------------------------x 100 san lng 220,000 3000 = -------------------- x 100 = 98.6% 220,000 Overall effectiveness = OEE = 0.92 x 0.83 x 0.986 x 100 = 75.3 %45
VD 3 Lp rap ban t ngMt dy chuyn lp rap ban t ng hoat ng 1 ca ngay, 7.5 h/ca, 5 ngay/tun; thng lng k hoach 150 san phm/gi. San phm thc ho nhn c 2875 san phm/tun1.
Vn hanh sai lam cho may dng va khi ng lai trung binh 5 ln/h, mi ln 2 phut, va bo i san phm u tin (tn tht do dng ngn va tn tht cht lng).
2. Cac in cc bi mon va phai thay th 1 ln/tun, mi ln thay mt 1 h va phai loai bo 30 san phm
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VD 3 (tt.)3. H thng lam mat bi s c mi thang1 ln va mt 5h thay th 4. H thng canh chinh san phm bi lch lam 220 san phm bi loai bo 5. Cac truc loi khng ng nht kich thc, phai dng may iu chinh thng s vn hanh 3 ln.tun, mt 2.25 h va 24 san phm bi loai bo 6. H thng bec phun bi ket mt 15 phut/ngay xuc xa, gy ra tri hoan san xut. 7. H thng phun ri mt 5 phut mt ngay khi ng va dng may 8. Han ch n mon thit bi chuyn mach cn dng may mi 6 tun/ln thay th mt 6 gi .
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VD3 (tt.)Tinh toan tn tht: Availability losses = 1 x 60 phut (s 2) + 5 x 60/4 phut (s 3) + 2.25 x 3 x 60 phut(s 5) + 6 x 60/6 phut (s.8) = 600 phut /tun = 2 phut x 5 x 7.5 x 5(s.1) + 15 phut x 5 (s.6) +5 phut x 2 x 5 (s.7) = 500 phut / tun = 1 san phm x 5 x 7.5 x 5 (s.1) + 30 san phm (s.2) + 220 san phm (s.4) + 24 san phm x 3 (s.5) = 510 san phm /tun
Performance losses
Quality losses
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VD 3 (tt.)Thi gian chay may = 7.5 x 5 x 60 = 2250 minutes/week 2250 - 600 -------------- x 100 2250
% Availability
=
= 73%
% Performance
2875 = ----------------------- x 100 (2250-600) /60 x 150) 2875 - 510 -------------- x 100 2875
= 70%
% Quality
=
= 82%
Overall Equipment Effectiveness (OEE) = 0.73 x 0.70 x 0.82 x 100 = 42%
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Li ich hu hinh va v hinh cua TPM Hu hinh:o Tng nng sut Giam s c dng san xut t ngt Tng hiu qua tng th trang thit bi, may moc
o o o o o o
Giam sai sot trong quy trinh Giam phan nan khach hang Giam san phm va qua trinh san xut d dang Giam tai nan Giam s c nhim mi trng Tng cng s cai tin50
Hu hinh (tt.):o o o o o Thit hai tinh chinh giam Chi phi sa cha giang Giam chi phi nhn cng cho bao tri Giam chi phi nng lng Ty sut li nhun cng ty tng
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Li ich v hinh:o at n s t chu trong quan ly Ngi vn hanh lam chu thit bi cua ho Ho chm soc thit bi ma khng cn s chi dn nao
o T tin phat trin va co thai d can do, why not o Mi trng sach se, tng sang va anh sng hn o Tao hinh anh n tng cho khach tham quan, qua o tac ng tt n quyt inh mua hang cua hoc
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