設(shè)備自主維護(hù)

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1、WCM GroupAgricultural and ConstructionEquipmentAutonomous Maintenance自主維修Guidelines指導(dǎo)方針NH AGNH CEThere are two types of autonomous activities: one is focused on the areas with intensive machinery and the other on the areas with a high level of labor content.有兩種自主維修活動(dòng)，一是重點(diǎn)放在加強(qiáng)機(jī)器區(qū)域，另一個(gè)是勞力較多的區(qū)域。The act

2、ivity regarding the machinery is called Autonomous Maintenance and the activity regarding the organization of the work area is called Workplace Organization關(guān)于機(jī)器方面的活動(dòng)叫自主維修，關(guān)于工作區(qū)域組織的活動(dòng)叫工作場(chǎng)所組織。Autonomous Maintenance自主維修The autonomous maintenance is part of those activities that has as the main scope to

3、 prevent breakdowns and micro failures due to lack of basic conditions of the machines.自主維修是那些活動(dòng)的一部分，這些活動(dòng)能夠預(yù)防由于機(jī)器基本條件缺乏造成的損壞和小故障。The autonomous maintenance is not a technical activity, like the professional maintenance, but it must be learned and applied by all the people that interact everyday with

4、 the machines. Its based on the competencies of the operators and using the five senses and very simple tools like paint brushes to eliminate the dirt, plastic to protect the machinery etc.自主維修不是一種技術(shù)活動(dòng)，像專(zhuān)業(yè)維修，但是每天使用機(jī)器的人都要學(xué)會(huì)應(yīng)用此自主維修技術(shù)。它是在操作工能力基礎(chǔ)上的，用五官，使用很簡(jiǎn)單的工具，如用油漆刷來(lái)清除污漬，用塑料保護(hù)機(jī)器等。What is AM ? (1/2)什么是自

5、主維修？The typical operations of AM are cleaning, lubrication, adjustment of fasteners, parameters control, temperature control, noise and vibration control, minor repairs and minor improvements.自主維修典型的操作是清潔，上油，調(diào)節(jié)閥，參數(shù)控制，溫度控制，噪音和振動(dòng)控制，小修復(fù)和小改善。The AM is a systematic approach towards the machinery improvem

6、ent with the objective to autonomously manage, by the production operators, the inspections, the control and restoration of the basic conditions of the machinery eliminating the sources of dirt, through a strict application and a continuous improvement of the standards.自主維修是進(jìn)行機(jī)器改善的系統(tǒng)方法，擁有自主管理的目標(biāo)，由生產(chǎn)

7、操作工清除污漬來(lái)源，通過(guò)嚴(yán)格遵守運(yùn)用不斷改善的標(biāo)準(zhǔn)，進(jìn)行檢查，控制和恢復(fù)機(jī)器的基本條件。Regarding AM and PM, up to step 3, its very important to always keep separated the preventive activities amongst the two pillars.關(guān)于自主維修和專(zhuān)業(yè)維修，一直到步驟3，要一直將兩支柱中的預(yù)防性維修分開(kāi)很重要。What is AM ? (2/2)什么是自主維修？The machines can break because of deterioration, increasing of

8、 the stress that they should support, caused by the loss of basic conditions. Likewise they can break due to human errors or to design errors. 機(jī)器可能損壞，是因?yàn)槟p，所能承受的壓力增加，基本條件缺乏造成的。同樣，也可以是人為失誤或設(shè)計(jì)錯(cuò)誤造成的。Why do the machines break? (1/2)機(jī)器為什么會(huì)損壞呢？BREAKDOWN損壞損壞DETERIORATION磨損磨損EXCESSIVE SOLICITATIONS額外的引發(fā)額外的引

9、發(fā)SCARCE ROBUSTNESS不不夠耐用夠耐用1Lack of maintaining the basic conditions維修基本維修基本條件缺乏條件缺乏23465Lack of observancy of the operating conditions不遵守操作條件不遵守操作條件No restoration of the anomalies沒(méi)有對(duì)異物進(jìn)行沒(méi)有對(duì)異物進(jìn)行恢復(fù)恢復(fù)Design weakness設(shè)計(jì)不足設(shè)計(jì)不足Bad competencies of operators and maintenance people操作操作工和維修人員的能力差工和維修人員的能力差Exte

10、rnal influences: material, spare parts, environment ecc.外部影響外部影響：材料，備用零件，環(huán)境等：材料，備用零件，環(huán)境等。 Why do the machines break? (2/2)機(jī)器為什么會(huì)損壞？The deterioration happens as time goes on caused by a bad maintenance not able to “maintain” the basic conditions or by the bad competencies of the operators whom do not

11、 perform correctly the inspections.由于維護(hù)不當(dāng)，不能維護(hù)基本條件或能力差的操作工不能正確的完成檢查，時(shí)間久了就會(huì)發(fā)生磨損。The increase of stress and the excessive solicitations are due to operating errors (bad competencies of the operators), bad interventions or due to the fact that the operating conditions are not strictly observed by the o

12、perators and of the non observance of the basic conditions.由于操作失誤（操作工能力差），不良干涉或操作工不能?chē)?yán)格遵守操作條件及不遵守基本條件，導(dǎo)致壓力增加，額外的引發(fā)出現(xiàn)。The scarce robustness of the machinery is the results of errors or weakness of the designs of the machines or single components, of construction or installation errors. To avoid the de

13、terioration of the machinery, it is necessary to assure the maintenance of the basic conditions. This is possible through the preventive maintenance, activities carried out by the AM and PM pillars.機(jī)器不耐用是因?yàn)闄C(jī)器零件的設(shè)計(jì)、構(gòu)造錯(cuò)誤或不足，或安裝錯(cuò)誤。為了避免機(jī)器磨損，保證機(jī)器的基本條件很重要?？梢蚤_(kāi)展由AM和PM支柱執(zhí)行的維修活動(dòng)。In order to avoid errors done

14、by operators or maintenance people, who can generate the increasing of stress, training must be done.為了避免由能產(chǎn)生壓力增加的操作工或維修人員造成的失誤，必須要進(jìn)行培訓(xùn)。To avoid errors due to design weaknesses, the Early Equipment Management pillar takes part to solve the issues.為了避免由于設(shè)計(jì)不足造成的錯(cuò)誤，設(shè)備初期管理支柱要加入解決此問(wèn)題。AM: Objectives 自主維護(hù)：

15、目的In the first phase, the objective of the AM is the maintenance of the basic conditions of the machinery. This is achievable assuring the correct operating standards of the machinery, the cleanliness, the lubrication and safety.第一階段中，AM的目的是維護(hù)機(jī)器的基本條件。保證正確的機(jī)器操作標(biāo)準(zhǔn)，確保清潔，潤(rùn)滑和安全，這是可以實(shí)現(xiàn)的。The final scope of

16、 the AM is to stabilize the conditions of the machinery, improve their reliability and to obtain as a result the lengthening of their lifetime. AM的最終目標(biāo)是穩(wěn)定機(jī)器的條件，改善其可靠性并實(shí)現(xiàn)機(jī)器使用壽命的延長(zhǎng)。This presupposes the definition and the continuous improvement of the maintenance standards and the increase of the compe

17、tencies of the operators in terms of knowledge of the machines. A very important effect of the AM is the quality improvement of the machine regarding the product.這預(yù)示著維修標(biāo)準(zhǔn)的定義和不斷改善，及操作工就機(jī)器方面能力的增加。自主維修的一個(gè)非常重要的作用是涉及生產(chǎn)的機(jī)器質(zhì)量改善。Initial cleaning & inspection初步清潔和檢查Countermeasures against sources of contamin

18、ation處理污染來(lái)源的對(duì)策Initial standards初步標(biāo)準(zhǔn)General inspection全面檢查Autonomous inspection自主檢查Improvement of standards (workplace organization & housekeeping)工作場(chǎng)所組織和設(shè)備管理、保養(yǎng)標(biāo)準(zhǔn)的改進(jìn)Full-scale application of the autonomous maintenance system全面貫徹自主維護(hù)系統(tǒng)The Seven Steps of Autonomous Maintenance AM自主維護(hù)的7個(gè)步驟Step 1Step 2S

19、tep 3Step 4Step 5Step 6Step 7The 7 steps 7個(gè)步驟The scope of the first three steps is to generate changes in the machines, passing from conditions of dirtiness, of difficulty in cleaning the machines, hazardousness, slowness, unreliability and of breakdowns and stoppages to a condition of cleanliness,

20、safety, reliability, zero stoppages and zero breakdowns.前三步是為了改變機(jī)器，解決污穢情況及難以清洗的機(jī)器問(wèn)題，將危險(xiǎn)，緩慢，不可靠和損壞，停頓情況轉(zhuǎn)變?yōu)榍鍧?，安全，可靠，零停頓和零損壞狀態(tài)。 The step 2 is the most critical one for obtaining advantages that derive from AM. The activities of the first two steps are typically of a reactive approach. The application o

21、f steps 1-3 is the KEY to determine the basic conditions of the machine.第二步是AM取得優(yōu)勢(shì)的最關(guān)鍵步驟，前兩步是回應(yīng)方法的典型代表。步驟1到3的運(yùn)用是決定機(jī)器基本狀態(tài)的關(guān)鍵。The 7 stepsThe fourth and fifth step are finalized to generate a change in the people, in fact the inspections done directly by the operators creates comprehension and assumpti

22、on of responsibility towards what and how to control, even towards quality, and makes work easier. The operators gradually assume the capability to accomplish autonomously the maintenance activities just like a parent would do with the health of his children calling the doctor, that can be compared

23、to the maintenance technician in case of necessity for problems on the machinery. Its important to consider the fact that the implementation of step 4 is expensive in terms of time and money. Its important to pay attention to the cost benefit of this step in order to justify the implementation. The

24、activities of steps 3 - 4 -5 are typically of a preventive approach. 第4步和第5步是為了改變?nèi)?，?shí)際上由操作工直接執(zhí)行的檢查創(chuàng)造出對(duì)要控制什么，該如何控制及對(duì)質(zhì)量的理解和責(zé)任，并且是工作變得更加容易。漸漸地，操作工就有責(zé)任，有能力自主完成維修活動(dòng)，就像父母為了孩子的健康而找醫(yī)生一樣，這可以與萬(wàn)一機(jī)器出現(xiàn)問(wèn)題，必須要找維修技術(shù)員相比。就時(shí)間和金錢(qián)而言，考慮執(zhí)行步驟4的花費(fèi)很大很重要。為了證明此步的執(zhí)行是有效的，注意成本收益很重要。步驟3、4、5 是預(yù)防性方法的典型代表。The scope of the sixth and se

25、venth steps is to generate a long-lasting change in the maintenance management across a new management system of autonomous activities where the worker is responsible for his area in terms of quality and reliability of the machines.第6步和第7步是為了對(duì)維修管理進(jìn)行長(zhǎng)期的改變，形成新的自主活動(dòng)管理系統(tǒng)，該活動(dòng)中，工人們負(fù)責(zé)管理自己區(qū)域內(nèi)的機(jī)器的品質(zhì)和可靠性。Cont

26、ents of the 7 steps AM 自主維修的7個(gè)步驟的內(nèi)容StepContents Of Step步驟的內(nèi)容步驟的內(nèi)容0Education of machine function & condition對(duì)機(jī)器性能和狀態(tài)的學(xué)習(xí)1Initial Cleaning & Inspection初步的清潔和檢查2Countermeasures to eliminate sources of contamination and “hard to access” areas清除污染來(lái)源和難以清洗區(qū)域的對(duì)策3Develop provisional standards for cleaning, lu

27、brication & tightening制定清洗，上油和上緊的臨時(shí)標(biāo)準(zhǔn)4General Inspection Training & Instruction of the finalized standards全面檢查-對(duì)最終標(biāo)準(zhǔn)的培訓(xùn)和指導(dǎo)5Autonomous Inspection自主檢查6Reorganizing workplace & Standardization重組工作場(chǎng)所并標(biāo)準(zhǔn)化7Full Implementation of Autonomous Maintenance全面貫徹自主維修Motivation動(dòng)機(jī)Machine Change機(jī)器改變People Change人員改變

28、Workplace Change工作場(chǎng)所改變Restoration of Basic Conditions基本狀態(tài)的恢復(fù)Prevention of Deterioration預(yù)防磨損Optimize Standardize Self Management使自使自身管理最優(yōu)化，標(biāo)準(zhǔn)身管理最優(yōu)化，標(biāo)準(zhǔn)化化2ELIMINATION OF CAUSES OF LOSS清除損失原因清除損失原因3STANDARD CLEANING LUBRICATION標(biāo)準(zhǔn)清洗潤(rùn)滑油標(biāo)準(zhǔn)清洗潤(rùn)滑油4GENERAL INSPECTION全面檢全面檢查查5INDEPENDENT INSPECTION獨(dú)立檢查獨(dú)立檢查6AREA

29、 CONTROL AND MANAGEMENT區(qū)域控制和管理區(qū)域控制和管理7COMPLETE APPLICATION OF AUTONOMOUS MAINTENANCE自主維護(hù)的全自主維護(hù)的全面運(yùn)用面運(yùn)用INITIAL CLEANING初步清潔初步清潔1THOROUGH ELIMINATION OF DIRT FROM PLANTS對(duì)工廠(chǎng)污垢的徹底清除LEARNING THAT CLEANING IS INSPECTING學(xué)習(xí)“清潔就檢查”REMOVAL OF CAUSES OF DIRT/LOSSES除去污垢/損失原因REMOVAL OF OBSTACLES TO ACTIVITIES除去阻

30、礙活動(dòng)的障礙物REDUCTION OF CLEANING, LUBRICATION TIMES減少清潔，上油時(shí)間DEFINE CLEAR, SIMPLE CLEANING, LUBRICATION, TIGHTENING CONTROL STANDARDS; SPECIFY TIMES AND FREQUENCY定義清潔，簡(jiǎn)單的清洗；固定控制標(biāo)準(zhǔn)；指定次數(shù)和頻率IMPROVE THE ABILITY TO MAKE A GENERAL INSPECTION OF THE PLANT ACCORDING TO STANDARDS AND MANUALS根據(jù)標(biāo)準(zhǔn)和指南來(lái)提高全面檢查工廠(chǎng)的能力IMP

31、ROVE THE ABILITY TO CARRY OUT INDEPENDENT INSPECTION, PREVENTIVE MAINTENANCE CYCLES AND TO USE THE CHECK-LISTS提高執(zhí)行獨(dú)立檢查，預(yù)防性維修周期，使用核對(duì)表的能力STANDARDIZE MONITORING OF THE EFFICIENCY, OF STOCKS, QUALITY, 對(duì)效率，庫(kù)存和質(zhì)量的標(biāo)準(zhǔn)華監(jiān)控IMPROVE DATA COLLECTION;改進(jìn)數(shù)據(jù)收集MANAGE THE EQUIPMENT AND TYPE CHANGES管理設(shè)備，類(lèi)型改變INTEGRATED M

32、ANAGEMENT OF AUTONOMOUS MAINTENANCE WITH REGARD TO OTHER ASPECTS OF TPM AND PURSUIT OF CONTINUOUS PERFORMANCE IMPROVEMENT GOALS涉及到TPM其它方面的自主維修的綜合管理，追求，完成不斷改善目標(biāo)The 7 steps of autonomous maintenance 自主維修的7個(gè)步驟Timetable時(shí)間表Average time of implementation of the first 4 steps of AM自主維護(hù)的前自主維護(hù)的前4步執(zhí)行的平均時(shí)間步執(zhí)行的

33、平均時(shí)間0 - 2 nd. Step0-2步步3 rd. Step第第3步步Model Area示范區(qū)示范區(qū)100 days100天天1 year1年年3/6 months3到到6個(gè)月個(gè)月Extension of the 3 rd. Step to all the plant將第將第3步擴(kuò)展到步擴(kuò)展到整個(gè)工廠(chǎng)內(nèi)整個(gè)工廠(chǎng)內(nèi)Implemetation of 4 th. Step on the model area在示范區(qū)在示范區(qū)執(zhí)行第執(zhí)行第4步步 Preliminary activities necessary for a correct definition and implementation

34、 of AM: 正確定義和執(zhí)行AM所必需的初步活動(dòng)： Matrix C of Cost deployment analysis and individualization of losses due to breakdowns.成本部署分析的C矩陣及由損壞造成的損失的特性 Machine classification機(jī)器分類(lèi). Target definition: eg. Reduction of 90% cleaning time on the model area, max 1 breakdown per month on model area, zero breakdowns on th

35、e critical machine due to lack of basic conditions.目標(biāo)定義：如，示范區(qū)有90%的清潔時(shí)間減少，每月示范區(qū)最多損壞一次，由于基本條件缺乏的重要機(jī)器實(shí)現(xiàn)零故障。 Individualization of model area.使示范區(qū)個(gè)性化 Team composition.團(tuán)隊(duì)合成 Planning of AM projects. AM項(xiàng)目的計(jì)劃Step 0 Preparation 步驟0-準(zhǔn)備Paint shop噴漆車(chē)噴漆車(chē)間間Cab AssemblyTractor AssemblyDriveline AssemblyStep 0 Model

36、 Area 步驟0-示范區(qū)Training of the operators of the model area done by the maintenance guys “the team leader and the operators must become owners of the machine” (explain how the deterioration occurs, diffuse the knowledge regarding the importance of safety during AM activities, develop knowledge on how t

37、he machine works) and analysis/execution of functional schemes of the machines.由維修人員執(zhí)行的示范區(qū)的操作工的培訓(xùn)，“小組領(lǐng)導(dǎo)和操作工一定要成為機(jī)器的擁有者” （解釋磨損是如何發(fā)生的，在自主活動(dòng)期間，傳播安全重要性方面的知識(shí)，開(kāi)發(fā)機(jī)器是如何運(yùn)作方面的知識(shí)）并分析或?qū)嵤?duì)機(jī)器有作用的計(jì)劃。 Predisposition of all necessary materials for AM ( Rags, detergent, paint brushes, Tags, formats for data collectio

38、n etc.) AM中所有必需材料傾向的狀態(tài)（碎片，清潔劑，油漆刷，標(biāo)簽，數(shù)據(jù)收集的版式等）Step 0 Model Area 步驟0-示范區(qū)Step 0 Preparation 步驟0-準(zhǔn)備Input輸入輸入- Matrix C of Cost Deployment成本部署C矩陣- Machines classification機(jī)器分類(lèi)Output輸出輸出- Radar chart of the team小組雷達(dá)圖- Masterplan including activities for each step, audits and corrective actions necessary f

39、or solving the criticalities found during the audits總體規(guī)劃，包括每一步的活動(dòng)，審核和處理危險(xiǎn)程度所必需的矯正行為，該危險(xiǎn)程度是審核過(guò)程中發(fā)現(xiàn)的。Team團(tuán)隊(duì)團(tuán)隊(duì)- Operators/Maintenance people. The responsible of the team is the Pillar leader of the plant操作工/維修人員，團(tuán)隊(duì)中的責(zé)任人是工廠(chǎng)內(nèi)的支柱領(lǐng)導(dǎo)。Tools工具工具- One Point lessons to develop the skills of the operators開(kāi)發(fā)操作工技能

40、的單點(diǎn)課程- Radar chart雷達(dá)圖KPIs關(guān)鍵業(yè)績(jī)指標(biāo)關(guān)鍵業(yè)績(jī)指標(biāo)- Know-how achieved by the operators and measured with the number of OPLs and with a in-out test of step 0; 由操作工取得的技能并由單點(diǎn)課程數(shù)量和步驟零的內(nèi)外測(cè)試進(jìn)行衡量- number of operators involved in the model area加入示范區(qū)的操作工人數(shù)Remarks備注備注- OPL on safety before starting AM activities開(kāi)展AM活動(dòng)前的安全

41、單點(diǎn)課程- From step 1 to step 2 foresee an involvement of the PM team in order to increase and consolidate the knowledge of the operators regarding the activities of cleaning, inspection, lubrication and control.為了增加，鞏固操作工在清潔，檢查，上油和控制方面的知識(shí)，步驟1到步驟2預(yù)知有PM團(tuán)隊(duì)加入。Step 1 Initial Cleaning 步驟1- 初步清潔Initial cleani

42、ng and inspection in order to remove dust and dirt that are the sources of deterioration of the machines.為了除去灰塵和污垢，要進(jìn)行初步的檢查，此灰塵和污垢是機(jī)器磨損的來(lái)源。 Remove dust and dirt of all the parts of the machine.除去機(jī)器上所有零件上的灰塵和污垢。 Hang tags on the machine showing all the anomalies, sources of contamination, hard access

43、 zones which can cause quality defects.在機(jī)器上掛上標(biāo)簽，展示出可能造成質(zhì)量缺陷的所有的異物，污染來(lái)源，硬的接觸區(qū)。 Remove all useless objects and create tidiness and cleanliness.移走所有無(wú)用的東西，創(chuàng)造整潔，清潔的環(huán)境。 Write the list of anomalies記下異物清單 . . . CLEANING IS INSPECTING清潔就是檢查清潔就是檢查MACHINE CLEANED清潔的機(jī)器DIRT IS REMOVED, CHIPS, SCRAPS ARE REMOVED除

44、去了污垢，碎片，廢料THE ELEMENTS OF THE MACHINERY ARE TOUCHEDWEAR AND DOWNGRADING IS PREVENTED預(yù)防了磨損和降格THE PLANT IS KNOWN工廠(chǎng)被大家所知IRREGULAR FUNCTIONING IS IDENTIFIED不規(guī)則的機(jī)能已被鑒定WEAR IS CHECKED 磨損已被檢查PREVENTION預(yù)防use mans 5 senses Appropriately適當(dāng)?shù)厥褂萌说倪m當(dāng)?shù)厥褂萌说?種感覺(jué)種感覺(jué)Step 1 Initial Cleaning 步驟1-初步清潔Operators learn that

45、 cleaning is inspection 操作工學(xué)習(xí)清潔就是檢查 improving their ability to trace minor problems and to discover irregularities during cleaning在清潔期間，提高追蹤小問(wèn)題，發(fā)現(xiàn)不整齊東西的能力。Aims of Initial cleaning 初步清潔的目標(biāo)初步清潔的目標(biāo)Step 1: Initial Cleaning 步驟1：初步清潔Ill start to clean with a ragI have also got to inspect the inside the of

46、 machine Too much grease! The covers missing! The oil level isnt visible! Too much dirt and not enough grease Excess leakage of oil This way, Ill trace all the faults! The pressure is OK Continuous tagging 不停的加標(biāo)簽不停的加標(biāo)簽Indication of issue of tag指出標(biāo)簽上的問(wèn)題Short circuit due tosimple problems小問(wèn)題造成的短路Repet

47、itive (chronic)Causes unknown反復(fù)出現(xiàn)的（長(zhǎng)期的）未知原因List of tags標(biāo)簽清單標(biāo)簽清單Tags attached 附上的標(biāo)簽Tags removed 去掉的標(biāo)簽Action行動(dòng)行動(dòng)Solving of theProblem問(wèn)題的解決Team Leader +BTU Leader +GroupTeam Leader +BTU Leader +Maintenance +Aut. Maint. Resp. Step 1: initial cleaning 步驟1：初步清潔 Step 1 Initial Cleaning 步驟1-初步清潔In this phas

48、e the operators, after receiving the training on safety, how to clean, which tools to use for the activities and how to pay attention in order not to create damages to the machine, they can start the initial cleaning. Its important to remove all the dirt, find all defects, anomalies and hidden broke

49、n things placing AM tags where the problems are.為了不給機(jī)器帶來(lái)?yè)p壞，此階段中的操作工在受到安全，怎樣清洗，活動(dòng)中使用哪種工具，如何注意培訓(xùn)后，他們?yōu)榱瞬唤o機(jī)器帶來(lái)?yè)p壞，此階段中的操作工在受到安全，怎樣清洗，活動(dòng)中使用哪種工具，如何注意培訓(xùn)后，他們可以開(kāi)始進(jìn)行清洗了。除去貼上可以開(kāi)始進(jìn)行清洗了。除去貼上AM標(biāo)簽地方的所有污垢，找出所有缺陷，異物和隱藏的損壞東西很重要。標(biāo)簽地方的所有污垢，找出所有缺陷，異物和隱藏的損壞東西很重要。 Step 1 Initial Cleaning 步驟1-初步清潔 Step 1 Initial Cleaning 步驟

50、1-初步清潔Output輸輸出出- List of all the anomalies assigning responsibilities and deadlines.列出所有的異物，指明歸屬責(zé)任和截止時(shí)間- Quantification of cost benefits of the step量化此步中的成本收益- Suggestions建議- Hours of training and/or OPLs培訓(xùn)和/或單點(diǎn)課程的時(shí)間- Plan of AM activities for cleaning AM清潔活動(dòng)的計(jì)劃Team團(tuán)團(tuán)隊(duì)隊(duì)The activity involves all the

51、 operators of the Model Area and it is guided by the Pillar leader. At the launch of the first AM activity, its recommendable that the plant manager is present and actively participates, to create involvement and to give the right commitment.此活動(dòng)中包括了示范區(qū)內(nèi)的所有操作工，由支柱領(lǐng)導(dǎo)指導(dǎo)。第一個(gè)AM活動(dòng)開(kāi)展時(shí)，可以推薦廠(chǎng)長(zhǎng)出席并積極參加，呼吁人們參加并

52、給出適當(dāng)?shù)脑u(píng)論。Tools工工具具AM tags must be used placing them near the individualized anomalies or can be used to suggest an improvement. AM標(biāo)簽可被放在個(gè)別異物旁或被用于提出改善建議。The AM tags, usually, are blue if solved by operators and red if solved by maintenance people.該AM標(biāo)簽若是由操作工解決的就是藍(lán)色，若是維修人員解決的就是紅色。KPIs 關(guān)鍵業(yè)績(jī)關(guān)鍵業(yè)績(jī)指標(biāo)指標(biāo)- Num

53、ber of AM tags per week ( consider that for an average complex machine, the number of tags after two/three weeks of activities of cleaning and inspection in order to be considered a success, it should be around 300/400 tags.)每周的AM標(biāo)簽數(shù)（對(duì)于復(fù)雜程度一般的機(jī)器，考慮其2到3周的清潔檢查活動(dòng)后的標(biāo)簽數(shù)量，為了成功，標(biāo)簽數(shù)應(yīng)為300到400左右。）- Implementa

54、tion rate (Tags)執(zhí)行比率（標(biāo)簽）- Number of quick kaizens快速改善數(shù)量- Savings on technical cleanings技術(shù)清潔方面的節(jié)省- Regarding the calendar: hrs/week, hrs/week of overtime for AM activities關(guān)于記錄表：AM活動(dòng)超時(shí)的時(shí)間（小時(shí)/周）Remarks備注備注-Organize the activities without interference with production organizing the stoppages or organizi

55、ng when the machines are stopped (night shift, Saturdays, Sundays)組織停產(chǎn)活動(dòng)，組織停頓或在機(jī)器停止時(shí)組織（夜班，周六，周日）- Assure maximum involvement of the people on the shop floor : e.g. Painting the floor of the model area white so that everyone can “see” the sources of dirt and so that everyone understands the responsib

56、ility of keeping the workplace clean.確保車(chē)間人數(shù)最大量的參加：如，將示范區(qū)噴為白色，以便大家都能看到污垢來(lái)源，并讓大家明白保持工作場(chǎng)所清潔的義務(wù)。- Go deep in the analysis of each component to understand the necessity to lubricate even involving the vendor. We are usually convinced that what we lubricate is enough but if we go in detail we find out tha

57、t there is many other things to lubricate.深入分析每個(gè)零件，明白上油的必要性，即便是聯(lián)系賣(mài)方。通常我們都相信我們所上的油足夠了，但是再仔細(xì)看來(lái)，還有許多其它東西要上油Step 2 Countermeasures against sources of contamination步驟2-清除污染來(lái)源的對(duì)策 Individualize the sources of contamination and the hard access zones. 個(gè)別加以考慮污染來(lái)源和硬的接觸區(qū) Find countermeasures for the sources of

58、contamination and the hard access zones.找出污染來(lái)源和硬接觸區(qū)對(duì)策。 Reduce time for cleaning, inspection and lubrication.清潔，檢查和上油的時(shí)間減少。Step 2 countermeasures against sources of contamination 步驟2-清除污染來(lái)源的對(duì)策Plate coverLow cost, easy to apply成本低，易于應(yīng)用Box typeLow cost, veryEffective成本低，很有效Change the materialto plastic

59、, rubber orsheet steel將材料變成塑料制品，橡膠或鋼板Step 2 Countermeasures against sources of contamination 步驟2-清除污染來(lái)源的對(duì)策BeforeBefore之前之前AfterAfter之后之后Installation of tray to collect chips and oil from machining 安裝托盤(pán)來(lái)收集加工時(shí)安裝托盤(pán)來(lái)收集加工時(shí)漏出的碎片和油漏出的碎片和油Contamination with chips and oil from machined parts機(jī)械零件上的碎片和油漬機(jī)械零件上的

60、碎片和油漬污染污染Cleaning Time Reduction清潔時(shí)間的減少清潔時(shí)間的減少M(fèi)achine: COMAU Transfer Line Area: Gear Box機(jī)器：機(jī)器：COMAU 傳遞線(xiàn)區(qū)域：傳動(dòng)箱傳遞線(xiàn)區(qū)域：傳動(dòng)箱Before之前之前After之后之后Other results:其它結(jié)果：其它結(jié)果：Cleaning Time (Minutes/day)Problem: difficult access due tothe shape of the covers問(wèn)題：由于蓋子的形狀而難以接近Countermeasure: installation ofmesh cover

61、s with safety devices對(duì)策：安裝安全裝置-網(wǎng)狀蓋子-53%EXAMPLEStep 2 Countermeasures against sources of contamination 步驟2-清除污染來(lái)源的對(duì)策-Extension to 6 similar transfer machines 延伸至6種類(lèi)似的轉(zhuǎn)移機(jī)器- Elimination of floor slickness消除地板的光滑消除地板的光滑Step 2 Countermeasures against sources of contamination Action Plan步驟2-清除污染來(lái)源的對(duì)策-行動(dòng)計(jì)劃

62、Step 2 Countermeasures against sources of contamination 步驟2-清除污染來(lái)源的對(duì)策Step 2 Countermeasures against sources of contamination 步驟2-清除污染來(lái)源的對(duì)策Output輸出輸出- List of all the sources of contamination and countermeasures for their the elimination. 列出所有的污染來(lái)源并找出相應(yīng)的清除對(duì)策Team團(tuán)隊(duì)團(tuán)隊(duì)- The activity involves all the ope

63、rators of the Model Area and it is guided by the Pillar leader.該活動(dòng)包括示范區(qū)的所有操作工，且由支柱領(lǐng)導(dǎo)指導(dǎo)。Tools工具工具- Quick kaizens: PDCA activities of problem solving 快速改善：解決問(wèn)題的PDCA活動(dòng)KPIs關(guān)鍵業(yè)績(jī)指標(biāo)關(guān)鍵業(yè)績(jī)指標(biāo)- Number of implemented countermeasures individualized.個(gè)別加以考慮的對(duì)策的實(shí)施數(shù)量- Cleaning time reduction清潔時(shí)間的減少- Lubrication time

64、reduction.上油時(shí)間的減少- Inspection time reduction.檢查時(shí)間的減少- Cost benefit analysis of the step.此步的成本收益分析- Breakdown trend on the critical machines重要機(jī)器的損壞趨勢(shì)Remarks備注備注- In the cost benefit analysis, take in consideration also the reduction of the cleaning time of the technical cleanings executed by external

65、 contractors.在成本收益分析中，也考慮由外商執(zhí)行的技術(shù)清潔時(shí)間的減少。- Calculate also the savings coming from the reduction of materials and energy directly linked with the sources of contamination (eg. Oil ecc.)也計(jì)算直接聯(lián)系到污染來(lái)源的材料和能源的減少。（如：油等）Step 3 Initial standards 步驟3-初步標(biāo)準(zhǔn) Create initial standards for cleaning, inspection, lub

66、rication, tightenings, visual controls, that allow the operations with less time and efforts ( specificating which part of the machine, time, frequency, gauge setting management, assignement of tasks and responsibilities.為清潔，檢查，上油，固定，可視化控制創(chuàng)建初步標(biāo)準(zhǔn)，用較少的時(shí)間和努力進(jìn)行操作，指明機(jī)器的某個(gè)部分，時(shí)間，頻率，設(shè)置管理的標(biāo)準(zhǔn)尺，任務(wù)和責(zé)任的分配。 Improve the effectiveness of the standards introducing visual management. 提高介紹可視化管理標(biāo)準(zhǔn)的有效性。 Reduce to zero all breakdowns due to lack of basic conditions (lack of AM) of the critical machines.將由于關(guān)鍵機(jī)器缺乏基本條件（