TPM

TPM

TPITPMTPITotal Productivity InnovationTPI TPMTotal Productive Maintenance TPITPMTPITPMTPITPM1997TPITPM30

2002500500500500UT()5002.74%20015001.06%0.79%3.53%2.04% TPM 500

21 TPM

(TPI)(6)T P M : : Boom - Up500TPM

TPM 1- BM 2- CM 3- PM 4- MP 5- PM 19501950195519601960GETPMPMBreak down MaintenanceCorrective MaintenancePreventive MaintenanceMaintenance PreventionProductive maintenance

T P M 1.LG

2.VOLVO EUROPAVWSAAB-VALMETSOLLAC.FOSMBKRENAULTFIAT

3.FORD MOTORYAMAHAP&GALCOACODAKTPM

TPM 1020304050-----22632652211181281416162251294142

TPM . ( 7 ) ( 28 ) ( 3 ) ( 39 ) ( 12 ) 5 . ( 8 ) ( 21 ) . ( 23 ) 4 2 (13) (90) (22) (6) (17) 1

TPM(Total Productive Maintenance)TotalProductiveMaintenanceTotal Productive ManagementTPMTotal Perfect ManufacturingTotalProfitableManagementTotal Plant ManagementTPM

TPM TPM TPM TPM

( 1 ) (PM) ( 2 ) ( MP-PM-CM ) ( 3 ) TPM T P M 1. (). 2. PM. 3. . 4. . 5. ,PM.

TPM,LC, 0

(1) PM

(2) MP-PM-CM(3) (4) TPM

TPM 8 I I

5 S

STEP1 STEP()2 STEP (/)3 STEP()4 STEP()5 STEP()6 STEP()7 STEP()TPM 7STEP

MaintenanceTPMTPMEffectTimeGapImprovementStart 1Start 2Start 3

TPM3- -- -- -

TPM

TPM

TPM3TPM = PM + ZD + SG

(Preventive Maintenance)-()----

0 (Zero Defect)- 0 -0

(Small Group Activity)---

TQC TPM TPMPMZDG=++

PRODUCTIVITY 97%(D),92%(N) 2.2(A),1.7(I) 1/20(I),1/15(S) 1.5(T)QUALITY 60%(A),90%(T) 0(T),1/9(D) 1/4(Y),1/2(N)LOT OUT 0(T)COST 50%(R),30%(A)energy 1/2(I,D) 40%(A),60% (K) 1/2(I)DELIVERY 40%(T),50%(S) 1/2(A) 1.3(I,T) 60%(T)SAFETY 0 0 0MORALE 37(I),28(O) 30(I),5(T) 7(I),2(N) TPM

TPM4 TPM0000

TPM12

1. TPM2. TPM(,,)3. TPM ,,, 4. TPM5. TPM 6. TPM KICK-OFF7.

8. MP 9. 10. 11. 0012. TPM World Best 7.1 7.2 7.3 7.4 TPM

TOP TOP ( = ) 1. TPM 10

TPM

1. 2. 3.

7PDCA 34

6. 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. 6. 1ST 2ST . 3ST 4ST 6ST 5ST

1. 2. 3. 4.

1. 1~3 STEP2. 4~5 STEP3. 6~7 STEP(), . ()(,,), (,) (,MP)(,) (,,() (,) .

7 STEP

TPM STEPSTEP..

5 S 0./..- AREA MAP

1..4LIST- LIST

2/.. - PM

3..- LIST-SUB-Theme-OPL

4.. - - Manual- Manual

5...0- system flow chart- check sheet

6... - CPK- FMEAFTA...

7.TPM./PDCA- sheet- MtbfMttrsheet- sheet

1STEP

1234.-

TPM12 1. TPM ?2. ?3. ?4. ?5. , ?6. , 7. , ?8. ?9. ?10. , ?11. ?12. STEP ?

TPM BM PM STENDWHY5WHY

TOP ,(Impowerment)1)TOP2)3) TOPTOP1)2)TOP3) TOP1)2)3)SYSTEM

3 TOP3 33 TOP 3TPMTOP DOWNBOTTOM-UPTPMTPM33 TPM33

TPM

TPMCEO1 231TPM 2 TPM

. . . . . . . . . . TPM 1. . 2. . 3. 4. 05. TPM TPM6. TPM

TPM

Money()Man Material Method Production ControlQuality ControlCost ControlDelivery ControlSafety & PollutionManpowerAuthorizationPlant Engg.&Maintenance InventoryControl(P) (Q)

(C)

(D)

(S)

(M)

Human RelationMethod

=InputOutput

2.

3. ()

1. : ManMachine ()Material ()MethodProduction ()Quality ()Cost ()Delivery ()Safety (,)Morale ()2. : (INPUT:4M)(OUTPUT : PQCDSM)/

MP LC(Life Cycle)(Initial Cost)TOTAL COST = / = /

(Planned M) (Unscheduled M)( Preventive M )

( Corrective M )

( Breakdown M ): ( Time Based M ): ( Condition Based M )( Emergency M ) ) M: Maintenance

1234MTBFMean Time Between Failure MTTRMean Time To Repair 2

Sheet7

MTBF

Sheet1

NO

1MASKLIFTER RELAY2LY4LY36,185

2MASK#1#236,162

3BM/SRYUNL/D36,217

4BM/SRY#11.5KW1.8KW36,161

5SRY#236,163

6AL(BREAK)36,216

736,220

8B/P36,192

9,36,342

10AGINGAG336,373

11AGINGRASTER AGING BARCODE36,162

12ITC17"SET36,162

NO

13COATINGINVERTER36,192

14BM#236,190

15BM/SRY#236,219

16BM/SRY36,341

17BM/SRYSHUTTER36,371

18BM/SRYDIVERTER36,402

19AL#1L/D36,190

20AGING36,341

21AGING36,310

22F-36,280

23ITCHOLDER(28)36,249

&P &N

Sheet6

BM/SRY

10/2

BM/SRY11/15

BM/SRY11/E

BM/SRY11/E

BM/SRY12/E

BM/SRY11/E

B/P12/E

B/P10/E

BM/SRY12/E

10/E

A/G11/E

A/G12/E

ITC12/E

Sheet2 (2)

BM/SRY MTBF=115Hr MTTR=10Min

99/9/15-12/31

1

6

BM/SRY MTBF=200Hr MTTR=8Min

2000/1/1-6/30

2

2

BM/SRY MTBF=350Hr MTTR=5Min

2000/6/30-12/31

3

3

1

Sheet2

123456

2SCHEDULE

Sheet1 (2)

NO98'99'

#1#2#1#2#1#2

11003311756392501000

2331227678863010001000

3166126250

4BM558147197150250

5SRY433580120150200

6166151126175250300

71186621375253501000

836812724218550035098'99'

997221109525300700SRY39100200

NO98'99'

#1#2#1#2#1#2

116112611108

2301930291512

3286915

4BM151182388

5SRY1614121488

61318172088

71610172188

8182412178898'99'

918143272812SRY15138

SRY MTBF

SRY MTTR

Sheet4 (2)

6

TEAM

OJT

Sheet5 (2)

MTBF=MTTR=

LOSS

LOSSJOB CHANGEPILOT

MTBFMean Time Between Failure Hr

MTTRMean Time To Repair Min

1

2

3

4

Sheet3

NO

1

2

3

4BM

5SRY

6

7

8

9

(MTBF)(MTTR)

8 = 100

() = 100=98% = 0.854 0.488 0.98 100 = 40.84 ( % ) 8 = 100

() = 100=85.4%

. -. - 400 - 8400

Sheet1

48070

480

TPM STEP

TPM

6 .PROJECT60NECK.

() . . . 6PMIEQCVE 1. NECK 2. 3. 3 PJT

4M 6 = 24LOSS4M6

Machine(Hour Loss)Material(Ton,Kg loss)Man(Hour loss)Method(Control loss)

16LOSS

= Energy = = (/ ) 100 = ( / ) 100 = ( / ) 100 = = { ( - ) / } 100 = { ( Cycle time ) / }100 = { (- ) / } 100 = ( ()/(() ) 100Energy = (Energy /Energy) 100

. .

,

( 1 ) . ( 2 ) , ( 3 ) . ( 4 ) . . ( 5 ) ( 6 ) PM

,

. =,= = 12 93 0 0

! ! -,, -,,, -,,, -,,

1 STEP7 STEP71 STEP2 STEP**3 STEP4 STEP

5 STEP6 STEPMP7 STEP PDCA

TPM

FuzicoshiPM 84JIPM TPM 10 STEP93TPM - 7STEP93 *88 PM91 PM8JIPM- 7 STEP BHSMART-98MODEL/5EQM5QA- / 100%QM-

QCD0MP

100%

0

0MP 0 0 / 5 S /

7 STEP1STEP2STEP3STEP4STEP5 STEP100%6 STEP100%7 STEP

TPM 0FOOL PROOF00

TPM

OJT OJT(On the Job Training) Off JT/TPM

(skill)

( 1 ) ? ( 2 ) ( ) .

1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 6 STEP

TPM

,()

5S5STPM

1 STEP 2 STEP *3 STEP *4 STEP *Lay-out * *5 STEP 6 STEP *307 STEP *TPM 7 STEP

1. 2. 3. 4M1E4. 5. 6. PROCESS7. STEP TPMSTEP

TPM

TPMTPM = PM + ZD + SG

(Preventive Maintenance)-()----

(Zero Defect)- 0 -0

(Small Group Activity)----TPM?

TPM?TPM

?

TPMTPM1 TPM2TPM

TPMTOP

TPMOPLOne Point Lesson

BRAIN STORMING 4 PRINCIPLES 4

TPM

!!