TPM在真空镀膜生产中的应用
摘要
我公司是一家主要从事投影显示系统光学部件的生产商,主要工艺为真空镀膜工艺。我公司生产的投影显示光学部件的销售额曾占全球的50%以上;然而随着市场的竞争日益激烈,公司面临着市场和成本的巨大压力。为了提高生产效率,适应市场变化,我公司导入了TPM体系,并在生产中具体实施应用。作者参加了实施的全过程,本文是对这个过程的总结。
论文简要介绍了TPM的理论及其发展历程;在对公司镀膜生产线上存在的问题进行了分析、研究的基础上,论证了TPM应用项目导入的必要性和可行性;导入和实施TPM项目的目的是,通过各种组织活动来持续改进,不断消除生产过程中的浪费,从而提升公司运营效率,降低成本。
论文的重点是总结TPM应用项目在公司镀膜生产线中的实施。其中,第一部分分析了作为TPM保障支柱的公司培训体系的现状,通过对培训流程和责任人的调整,有效控制了培训的流程,提高了培训的效果;第二部分总结了5S活动开展的做法,通过对现状的分析,制定出详细的5S计划和评估体系并予以执行。通过这些活动,提升了现场管理水平,保障了设备工作处于良好的环境中,降低了设备因为自然劣化而产生故障的可能性;第三部分描述了如何建立全新的设备管理体系,说明如何通过维护管理、维修管理、备件管理,保障设备在整个生命周期都处于可控状态。通过计算机化的设备管理软件和SPC等工具的使用,使得设备处于良好的维护中,减少了设备的故障发生的可能性,减少了设备的故障率;第四部分介绍了设备综合效率的计算方法,通过TPM活动对生产环节进行持续改善,减少生产过程中的六大损失,提高了设备的综合效率,降低了维修成本。
Our company is a manufacturer of coated optical components for projection display system; the key process is the vacuum optics coating. The company even enjoys more than half of market share of the global optical components in the projection display market, but with the growing of the furious competition, the company is under the unprecedented pressure. In order to increase the manufacturing efficiency for adapts the marketing grow, our company introduces and implements the TPM system in the production. The author takes active in the whole process. This thesis is the conclusion of this process.
In the thesis, the theory and the development of TPM system is introduced, and the existing problems in the coating process is analyzed; then the thesis demonstrates the necessity and feasibility of TPM implementation. In the mean while, the thesis presents the purpose of TPM’s application project is to improve the company operating efficiency and reduce the operation cost through the team activity, continuous improvement and constant elimination of the waste in the production.
The key point of the thesis describes the TPM application project in the key technology and process coating production line. In the chapter, Part 1 is analyzing the education system in the company, the training result was improved through the training procedure and the responsibility person was modified. The part 2 is focus on 5S activities, the detail 5S improvement plan and assessment system was setup based on the real situation. The on-site management and equipment working environment is improved through the 5S activities implement. Part 3 is present the new equipment management system was build up to control the whole life of equipment, such as repair working flow, maintenance working flow and spare parts management. The computerize equipment management system and SPC software was introduced to cut down the breakdown frequency of equipment also. Finally, part 4 introduce how to calculate the OEE, and describe how to improve it through reduce the six-big-lost of equipment.
论文简要介绍了TPM的理论及其发展历程;在对公司镀膜生产线上存在的问题进行了分析、研究的基础上,论证了TPM应用项目导入的必要性和可行性;导入和实施TPM项目的目的是,通过各种组织活动来持续改进,不断消除生产过程中的浪费,从而提升公司运营效率,降低成本。
论文的重点是总结TPM应用项目在公司镀膜生产线中的实施。其中,第一部分分析了作为TPM保障支柱的公司培训体系的现状,通过对培训流程和责任人的调整,有效控制了培训的流程,提高了培训的效果;第二部分总结了5S活动开展的做法,通过对现状的分析,制定出详细的5S计划和评估体系并予以执行。通过这些活动,提升了现场管理水平,保障了设备工作处于良好的环境中,降低了设备因为自然劣化而产生故障的可能性;第三部分描述了如何建立全新的设备管理体系,说明如何通过维护管理、维修管理、备件管理,保障设备在整个生命周期都处于可控状态。通过计算机化的设备管理软件和SPC等工具的使用,使得设备处于良好的维护中,减少了设备的故障发生的可能性,减少了设备的故障率;第四部分介绍了设备综合效率的计算方法,通过TPM活动对生产环节进行持续改善,减少生产过程中的六大损失,提高了设备的综合效率,降低了维修成本。
Our company is a manufacturer of coated optical components for projection display system; the key process is the vacuum optics coating. The company even enjoys more than half of market share of the global optical components in the projection display market, but with the growing of the furious competition, the company is under the unprecedented pressure. In order to increase the manufacturing efficiency for adapts the marketing grow, our company introduces and implements the TPM system in the production. The author takes active in the whole process. This thesis is the conclusion of this process.
In the thesis, the theory and the development of TPM system is introduced, and the existing problems in the coating process is analyzed; then the thesis demonstrates the necessity and feasibility of TPM implementation. In the mean while, the thesis presents the purpose of TPM’s application project is to improve the company operating efficiency and reduce the operation cost through the team activity, continuous improvement and constant elimination of the waste in the production.
The key point of the thesis describes the TPM application project in the key technology and process coating production line. In the chapter, Part 1 is analyzing the education system in the company, the training result was improved through the training procedure and the responsibility person was modified. The part 2 is focus on 5S activities, the detail 5S improvement plan and assessment system was setup based on the real situation. The on-site management and equipment working environment is improved through the 5S activities implement. Part 3 is present the new equipment management system was build up to control the whole life of equipment, such as repair working flow, maintenance working flow and spare parts management. The computerize equipment management system and SPC software was introduced to cut down the breakdown frequency of equipment also. Finally, part 4 introduce how to calculate the OEE, and describe how to improve it through reduce the six-big-lost of equipment.
引文
[1]李葆文.简明现代设备管理手册[M].北京:机械工业出版社,2004.5,17-23页
[2]岳华新,不学索尼.学三星-关于国内企业推行TPM的探讨[J].企业管理,2003,(10),60-61页
[3]崔继耀,TPM活动推行实务[M].广州:广东经济出版社,2004.1,14-87页
[4]李葆文.全面生产维护一从理念到实践[M].北京:冶金工业出版社,2005,38-124页
[5]刘承元. TPM与工厂全面改善[M].广州:广东经济出版社,2006.11,25-34页
[6]李葆文.国外设备管理模式及发展趋势[J].设备管理与维护,2000.7,50-81页
[7]岳华新.TPM实战[M].广州:广东经济出版社,2004.6,19-59页
[8]肖保生.设备管理系统[M].西安:西北工业大学出版社,1997.11,103-142页
[9]刘承元. TPM与工厂全面改善[M].广州:广东经济出版社,2006.11,12页
[10]铃木德太郎.TPM追求三个“为零”.中国设备管理,1992,(11),48页
[11]邱苑华,沈建明,杨爱华.现代项目管理导论.北京:机械工业出版社,2002.9,19-57页
[12]林永昌,卢维强.光学薄膜原理[M].北京:国防工业出版社,1990.5,126-157页
[13]刘胜军.精益生产-现代IE[M].深圳:海天出版社,2003.10,5-38页
[14]约瑟夫.M.朱兰,A.布兰顿.戈弗雷.朱兰质量手册[M],北京:中国人民大学出版社, 2003,(5),396-436页
[15]郁黎扬.“设备综合效率”在宝钢的应用与分析[J],化工设备与防腐蚀,2002,5, (3),165-168页
[16]李葆文.简明现代设备管理手册[M].北京:机械工业出版社,2004.5,103-132页
[17]李葆文.企业OEE计算问题的解决[J],广州大学学报(自然科学版)2002,(1)91-96页
[18]李金热,缪正余.设备综合效率OEE的计算[J],南京工业职业技术学院学报,2002,(4),10-13页
[19]许志玲.如何进行精益生产[M].北京:北京大学出版社,2004.12,117-143页
[20]王祖和.项目质量管理[M],北京:机械工业出版社,2004.1,33-75页
[2]岳华新,不学索尼.学三星-关于国内企业推行TPM的探讨[J].企业管理,2003,(10),60-61页
[3]崔继耀,TPM活动推行实务[M].广州:广东经济出版社,2004.1,14-87页
[4]李葆文.全面生产维护一从理念到实践[M].北京:冶金工业出版社,2005,38-124页
[5]刘承元. TPM与工厂全面改善[M].广州:广东经济出版社,2006.11,25-34页
[6]李葆文.国外设备管理模式及发展趋势[J].设备管理与维护,2000.7,50-81页
[7]岳华新.TPM实战[M].广州:广东经济出版社,2004.6,19-59页
[8]肖保生.设备管理系统[M].西安:西北工业大学出版社,1997.11,103-142页
[9]刘承元. TPM与工厂全面改善[M].广州:广东经济出版社,2006.11,12页
[10]铃木德太郎.TPM追求三个“为零”.中国设备管理,1992,(11),48页
[11]邱苑华,沈建明,杨爱华.现代项目管理导论.北京:机械工业出版社,2002.9,19-57页
[12]林永昌,卢维强.光学薄膜原理[M].北京:国防工业出版社,1990.5,126-157页
[13]刘胜军.精益生产-现代IE[M].深圳:海天出版社,2003.10,5-38页
[14]约瑟夫.M.朱兰,A.布兰顿.戈弗雷.朱兰质量手册[M],北京:中国人民大学出版社, 2003,(5),396-436页
[15]郁黎扬.“设备综合效率”在宝钢的应用与分析[J],化工设备与防腐蚀,2002,5, (3),165-168页
[16]李葆文.简明现代设备管理手册[M].北京:机械工业出版社,2004.5,103-132页
[17]李葆文.企业OEE计算问题的解决[J],广州大学学报(自然科学版)2002,(1)91-96页
[18]李金热,缪正余.设备综合效率OEE的计算[J],南京工业职业技术学院学报,2002,(4),10-13页
[19]许志玲.如何进行精益生产[M].北京:北京大学出版社,2004.12,117-143页
[20]王祖和.项目质量管理[M],北京:机械工业出版社,2004.1,33-75页