1. Autonomous maintenance (PM group activities). Japanese scholar Kiyoshi Nakajima regarded "autonomous maintenance by operators (group activities)" as "the biggest feature of TPM". TPM instills in all personnel from the top to the bottom the idea that "you are in charge of your own equipment," equips each operator with the skills to perform maintenance on your own, and takes the organizational form of conducting PM group activities.
The main contents of the PM team activities are: (1) According to the PM policy of the superiors, to develop the team's work objectives. (2) Carry out 5S activities. (3) Filling in point inspection records and analyzing the actual technical condition of equipment based on the data obtained. (4) To improve the productivity of equipment and reduce the six losses, analyze the causes of failures and study improvement measures. (5) Organize education and training to improve members' skills. (6) To check the completion of the group's objectives and evaluate the results.
2, 5S activities. Carrying out 5S activities is an important element in Japanese TPM autonomous maintenance. "5S" refers to organizing, reorganizing, cleaning, sweeping and sustenance. Because these five words of the Japanese pronunciation of the Roman alphabet first are S, so called "5S" activities. 5S specific meaning is:
A Organize ­ - the disordered things cleaned up, do not use things to clear away. B tidy up - the items classified neatly stored, need to be able to immediately get to hand. C clean - timely cleaning, do not let the dust, oil, debris to stay. D clean - the machine and equipment and operating site often keep -D Clean - often keep the machine and equipment and operating site clean and sanitary, so that dust, fumes, waste liquids, etc. fully discharged. E Quality - have a good demeanor and style, polite and disciplined; decided things must be observed. The first 4 S's are to be ensured and improved by the 5th S. If everyone in the enterprise can implement the "decided things must comply with" this guideline, equipment operating procedures, safety procedures, product quality standards, delivery date, etc. can be seriously fulfilled, the enterprise will certainly be able to achieve high quality, high yield, low consumption and safety.
3, point check. Carry out point check is another important element of TPM independent maintenance. The so-called point inspection, refers to a certain standard, the provisions of the equipment part of the test, so that the abnormal state of the equipment and deterioration can be found early. Equipment inspection is generally divided into daily inspection and periodic inspection, etc..
Daily spot check inspection cycle is mostly daily, weekly, usually within a month. Mainly by the operator is responsible for, to the human body five senses, the implementation of the main basis for the inspection is the inspection card. Regular inspection, the inspection cycle is generally in a week or more than a month, mainly by professional or maintenance personnel, relying on the human body five senses and specialized instruments to check the regular inspection card is generally prepared by the equipment technicians.
From the above analysis, it can be seen that the Japanese TPM attaches importance to preventive maintenance, and emphasizes the active participation of operators. According to Japanese experience, 60% to 80% of failures can be detected early through spot checks. Japan also compared the preventive maintenance of equipment with the human body's preventive medicine, equipment management is equivalent to "equipment health" management. Preventive medicine of the human body has daily prevention, health checks, early treatment and other aspects of preventive maintenance of equipment also has routine maintenance, regular checks and preventive repair measures. People's health should be cared for by themselves first, and the "health" of the equipment must also be cared for by the personnel using the equipment. Through the operator's cleaning, refueling, adjustment and daily inspection and full-time maintenance personnel (equipment doctor) of the regular inspection (health check), preventive repair (early treatment), you can delay the deterioration, reduce failures, improve the efficiency of the equipment, extend the service life of the equipment.
4, local improvement. There are many types of equipment failure, both regular failure, there are also irregular sudden failure. Therefore, rely solely on the implementation of preventive maintenance can not completely eliminate the fault, so TPM attaches great importance to the local improvement of equipment. The so-called local improvement, refers to the existing equipment to locally improve the design and transformation of parts, in order to improve the technical state of the equipment to better meet the production needs.
There are two types of local improvement. One is the mass of local improvement activities, it is closely integrated with the independent maintenance of the operating workers, the PM group composed of operating workers for the general defects of the equipment to list the subject, analysis and research, and put forward rationalization proposals. Then, they solve the defects such as oil leakage, inconvenient inspection, unsafe, inconvenient storage of tools and parts, etc. one by one by themselves. The factory takes the rationalization suggestion to realize the construction as an important index to evaluate the effect of TPM carried out by each unit. Second, for the design and manufacture of large sequelae or key equipment problems, by the equipment management department, maintenance department, production site personnel to form a design team, for the problem to spend a lot of effort to improve the design, eliminate defects, to achieve the required technical condition.
The Japan Institute of Plant Maintenance (JIPM) also to improve the efficiency of the local improvement of equipment, the establishment of independent maintenance system, the establishment of a planned maintenance system, improve the skills of operators and maintenance personnel, the establishment of the initial use of the equipment management system as the five pillars of the development of TPM, and also pay considerable attention to the latter three links.
In 1998, organized by the European Maintenance Alliance held in Croatia, Europe's 14th International Maintenance Conference, to promote full production maintenance as the theme of the General Assembly.
Steps to carry out full production maintenance
1, the introduction of TPM publicity and personnel training
2, the establishment of TPM promotion organization
3, the development of TPM basic guidelines and objectives
4, the development of TPM promotion master plan
5, the development of measures to improve the overall efficiency of the equipment
6, the establishment of the Self-maintenance system
7, Maintenance plan
8, Training to improve operation and maintenance skills
9, Establishment of pre-equipment management system
10, Summarization and improvement of the full implementation of TPM