1.,.. 2. (1) Flow + ( ) (2) Flow Flow (LINE) ) (LINE) ModelC/T LOSS DAT A Check Sheet ((%) (T PM) (LOSS) -
(3) () () LOSS LOSS LOSS LOSS (4) = 100 = 100 = 100 = 100 = 100 = 100 = 100 = 100 = 100 = 100 = 100 = 100
3. (1) :. - = 100 = 100(%) : (). Cycle T ime = 100(%) Cycle T ime :. Cycle T ime = 100(%) :. C/T = = 100(%) :.,, ( ). < = + + ( ) > - = 100(%) = 100(%)
:. = 100(% ) C/T = 100(%) = 100(% ) (2) -. :. ) : 8HR (480) (,.) :. = - : = - : = C/ T = - LOS S : = C/ T = - LOSS : LOSS (), : (:,, //, ), : (:,, ) () : () : (LOSS)
: : :, Model, :,,, :,, (T rouble,, ON.) :, :, :,(,) () : C/T :. C/T :. (3) Line = 100(% ) C/T = 100(%) (4) MT BF(Mean T ime Betw een Failure : ) t1 + t2 + t3 + + tn = () N
= 100(%) (5) MT T R(Mean T ime T o Repair : ) = ta + tb + tc + + tx () = 100(%) N ta tb tc td tx t1 t2 t3 t4 tn (6) C/T C/T, C/T C/T.. C/T () : 1 Cycle () () 1 Cycle : () 1 Cycle: +() () :.
4. (1) Input Output C/T : (+ )1 Cycle 24 A Model Cycle T ime : 2 : : 580 : 500 80 :60, Shop: 20 : 440 60 :30M/C:30 : 200, : 190 440 = 100 = 100 = 88.0% 500 C/T 2200 = 100 = 100 = 90.9% 440 190 = 100 = 100 = 95.0% 200 = 100(% ) = 0.88 0.909 0.95 100 = 75.9 % 500 = 100 = 100 = 86.2 % 580 = = 0.759 0.862 100(%) = 65.4 %
(2) LINE A B C D E F G Cycle T ime : 1 1.2 1.5 2 1.8 1.6 1.9 : Neck (1) Neck (2) Neck : NeckC/T :, (, DAT A) 24 Neck : D Cycle T ime : 2 : : 580 : 520 60 :60 : 440 60 D:30M/C:30, A D:20 : 200, : 190(FCHECK) 440 = 100 = 100 = 84.6% 520 C/T 2200 = 100 = 100 = 90.9% 440 = 100 = 190 100 = 95.0% 200 = 100(% ) = 0.88 0.909 0.95 100 = 73.1 % 520 = 100 = 100 = 89.7 % 580 = = 0.731 0.897 100(%) = 65.6 %
1(23),., (:, ()),.. 1. 1., 2.,,.. 1,, T rouble, (T ool). ( 3. ) 3.
4. 5. LOSS. SPEED LOSS. SPEED(CYCLE T IME) SPEED, SPEED LOSS. 3 LOSS SPEED DOWNLOSS.,.,. (,,, T OOL ).. 6. - = 100 = 100(% ) 7. LOSS, LOSS,. :, SPEED?,. T rouble(, ) LOSS... SPEED, LOSS. Cycle T ime = 100(%) - :, SPEED(CYCLE T IME) SPEED. SPEED, SPEED DOWN..
Cycle T ime = 100(%) Cycle T ime. 7. C/T C/T = 100(%) - C/T LOSS LOSS.,,,. 8. = 9.,,,,. =,,. T rouble 10.... 100%. 11. 6,,, (),,, LOSS 6LOSS. 6LOSS POINT. 1) LOSS :, LOSS. LOSSLOSS(, ). 2) LOSS : LOSS.,,
11. 6 12. LOSS LOSS 3) () LOSS, T rouble. LOSS LOSS 4) LOSS SPEEDSPEED. SPEED, DOWN, CHECKLOSS. 5) LOSS LOSS.,,. 6) LOSS () LOSS. LOSS,,, SKILL.,,.. LOSS LOSS. LOSSLOSS. LOSS LOSS LOSS.
. 13. Oil/., 14...., Output 15.. 90%.. 16.,.. UNIT,, 100%. UNIT. () ( ), 17.. 6LOSS.,, 8. (,, ) (, ) () (, ) () (, ) () (, LEVEL)
V- BELT. < > 17.. 3(3) 3T ension T ension.,,, Oil, Motor,, (, ). 18., (, ). 19. SKILL, ( ),. LOSS(, JIPM. (Phenomena) (Physical), (Mechanism) PM. Point List- Up. List- Up. 20. PM
T PM
1.
2.? - Life Cy cle,,, Follow - up. 6ST EP ST EP 1 ST EP 2 ST EP - DAT A -. -. - 3 ST EP 4 ST EP 5 ST EP 6 ST EP
3.
4. ST EP ST EP 1 ST EP 1) () 2) :, RANK, PM, PM 3) RANK 4) :,,,, MT BF,,. 5) (, ) 2 ST EP 1),, ( ) 2), 3), 4) PROCESS 3 ST EP 4 ST EP 5 ST EP 6 ST EP 1) DAT ASYST EM 2) SYST EM (,, ) 3) SYST EM 4),, 1) (,,,,, ) 2) FLOW 3), 4), (,,, ) 5) 1) (, ) 2) Flow 3),, 4), 1) 2) :,, MT BF, 3) :,, MT T R 4) COST DOWN:,
5.
6. 0 6 1),.,,,,,.. 2),.,,.,,,,,,,,,,,,,,,.,., 0,,,. 3).,,...,. 4).,,, V- BELT,,.,
5)..., 0.,.,.,.,, 6).,.,,,,.
7. FLOW
8. N O.
9.
NO 1,, ( ) 2, 3, 4 (A) 5 (B) 6 7,,,, QA,,., 8,, 9 / 10, 11, 12 (, ), 13,.,..,
10., - - - - - - - Machine Cycle T ime -, - -, - - -, - Overhaul -,, - -,, - Plant - - ( ) - Model Change/, - Process -, - Botton (,,,, ) -,,,, -, - Recycle., -,, -, - - - Process
11. - A - - B - C -, User -, A B -, C -, -, -,, - 2,, - 230,, A B C A B - T IMING C,,,,, ABC,.
12.
1 S T EPS HEET T OP 90 85 80 P O I N T 100% 80% 60% (1) (2) PM (3) RANK? 10? 5? 5?. 5? 5 PM PM? 5 PM? 5? 5? 5 PROCES S? 5 (4) LEVEL /? 10 MT BF MT T R? 10 MT BF? 10? 5? 5 (5) BENCH- MARK (6) BM?? 5 MT BFBM? 5, BM? 5 S T EP? 5 2 S T EP? 5
T PM () 1 : : (100) 1. 0 2. 1),, 2),,,,, 6LOSS 5 3 1 - T PM 5 4 3 0 /15,,,, Oil,,,,,,,, 2 3, 5 3 80%50%50% 5 4 5 4 3 2 5 4 3 2 3 2 1 0 2 1 0-2 1 0 - /22 3.,,,, 1), Oil,,, 3,,,, 2),,,, 3), 2 3,,, 80% 50%50% 5 4 4 3 2 1 3 2 1 0 3 2 1 0 2 1 0-3 2 1 0 /19 1 3 3-2 2
(100) 4.,,, 4 3 1 -,, Oil, 2 1 0 - (Oil),, Oil 2 1 0 - /10 5. 6., 7., 8. 80%50%50%,, 2 1 0 -, 2 1 0 -,,, 2 1 0 -, 2 1 0 -,Oil, 2 1 0 -, 2 1 0 - /14 : 3110 10 9 8 7 6 5 4 3 2 1 0,,,,, 50% 5 30% 4 30% 3 0 /5 1() 5 4 3 2 /5
2 ST EP - -,. -,. -.. -,. : 8.. 1 (?,?), 2 (,?,?) 3,, ()., /COST ( ) 4, ) 5 :,,, 6 50% 7 75% 8 90% )?, (,, ), ( ),,, :,,,LOT :,MODEL CHANGE,, :,
1. T rouble. 2.. 1. (,, ). 2.. 3.,,. 4. (). 5.. NO 1. 1)., Scale,,, 2). 3) CoverSeal,. 2. 3. 1) CoverSeal 2) 3) I- Mark,, (). 1).,..
3. 2). (). 3).. 4).,,. 5). 4. 5. 6. () 1).,. 2).,,. 1).. 2).. 1) (). 2) M P DAT A FEED- BACK(M P) 3) 7. SUB- T HEME SUB- T HEME 8. 1).SHEET " 2), T PM 3) 3ST EP
T PM () 2, 1 (10) 1, Oil, (20), (25) (5) (5) (5) (4) (4) (4) (3) (3) (3) (2) (2) (2) (0) (0) (0) (10) (8) (6) (4) (0) (5) (4) (3), (5) (4) (),, (5) (3) (2) (2) (0) (0) (10) (8) (6) (4) (0) (10) (8) (6) (4) (0), (10) (8) (6) (4) 60 ( ) (60) (48) (36) (24) (0) 48 = 90%,, = 70 80%, = 50%, = 20 30% (0)
3 ST EP.. - ( )..... - -.,. : 8. 1 2 3 4 5 6 7 8 ()......( ) ().....,. ()... A :, B :, C : () ( ), ( ), (), ( ) (), (). 1, 2 ST EP, (), 4. (CHECK SHEET ) - -. (,, ) (CHECK SHEET ) - 1. -,,. (, ) -, FILE, 1 -, 1,.
1,2,,. (,, ).., (NO 4) 1. (NO 4) (, ),,,,,. POINT. 2..,..,. (, ). 3... (),, 4.., POINT.
T PM () 3, 1 (5) (4) (3) (2) (0) (5) 2 (15) 2,,, ) (30) (10),,,, (5) (4) (3) (2) 70% 60% 50% (5) (4) (3) (5) (4) (3) (0) 30% 10 20% (2) (0) (2) (0) (10) (8) (6) (4) (0) (10) (8) (6) (4) (0) (5) (4), (3) (2) 10 7531 0 (5) (4) (3) (2) (0) 60 ( ) (60) (48) (36) (24) (0) 48 (0)
4 ST EP -,,.,. -,,,,. -. -. -,. : 8?. 1 2 3.? 4. 5 6 7 8 ()...
1 3 5() 1. 2. 1. (1 3 ),?,? One Point Lesson. 2. 1 3, 1) 3. 4 Check Sheet. 2) 4.. 1 3
T PM () 4 : : (100) 1 1 () 5 4 3 2 1 5 4 3 2 1 /15,, 10 9 7 3 1 1 3 (, ) 5 4 2 5 4 1 2 1 /20, (, ) 5 3 1,,,, 5 3 1, 5 3 1, POINT 5 3 1 /20 (, ) 5 3 1, 5 (, ) 5, 5
, 3 2 1, 2 1 0 5 4 3 2 1 /30 6LOSS One Point Lesson 5 3 10 7 3 1 1 /15
5 ST EP 1., 2. 1. Check Sheet(,,) 2. 1.....,.. * 1 4 5
T PM () 5 : : 4,, 5 4 3 2 1 5 4 5 4 5 3 3 2 1 2 1 4 2 1 5 4 2 1, 5 4 2 1 /30 4 5 6 5 3 2 1 6 5 3 2 1 (, ) /30
(, ) 8 6 4 2 1 8 6 4 2 1 T rouble One Point Lesson 8 6 4 2 1 /40
6 ST EP OPERAT OR 1. 2. 1. T heme,,.. 6LOSS, DAT A..,,. 2.,,,,,,,,,.,...
T PM () 6 : :. 5ST EP 5 4 5 4 5 5 4 3 3 3 1 1 1 /15 4 5, 10 9 5 1 (, ) 10 9 5 1,, 10 9 10 9, 10 9 5 1 5 1 5 1 / 60 PM, 8 7 Check 4 1 (List), 10 9 7 6 5 3 1 1 /25
7 ST EP 1 6 1. 2. 1. 1) DAT A,, 2). 3). 1). 2. 2). 3) DAT A.
1,, T PM,, ONE POINT LESSON 2., POINT
3. MEET ING COMMENT,, ) 2 31. 4 52 4.,,, follow
1.,, PR, 2. (SLOGAN,,, ),,, (, ) (, ) RULE, (,,, ) RULE, 3. 1,,. DAT A. (CHECK), 1 ( ),
2ST EP, 1,,,,,,,,,,,,,,. (,, ),,,,, //,, //.
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LIST - - - - - () ( ) - - -., (,, ) /,, ONE POINT (, ),,. (), (, ). ( ),. (), ().,.,,
, C- A- P- D- C- A 1. POINT,. (, ) (, ). (, ). (),. /, / /. / (CHECK SHEET ),.. (),,.. 3(, ). 2. /. /,.
P O I N T 1. 2.,,,,, 1. 1 1.,,,,, 2.,,, 3., / 4. 5. 3.,, 1.,,,,,, 2. / 3. 4. 5. 6. 7. 4. 1. 3,, 2. / 5. 1
T PM- 3
ONE POINT LESSON,,, /,,, 93 SIGN SIGN (, ) or (, SING) 1 T PM.
< 1> : : POINT 1.? (,,,,,) 2.,,? 3.? (,,,, AIR SET,, ) 4., /? (,, ) COMMENT 1.,,? ( 1) 2.,? 3.,?,? COMMENT 1.,,,? 2.,,,,?,? 3.,,? COMMENT 1.,,,,? : PAGE : : 1/2 5 4 3 2 1 1 2,,, 1 2, 1, 1 2 2.,? 3.? 1 21 2 5S 4.,,,,,,? COMMENT
POINT 1.? (, ) PAGE 2/2 5 4 3 2 1 2.? 3. LIST, / / LIST,? (,,,, O.P.L ) 4.,? 1 2 5. ONE POINT LESSON4/ 2/ 1/ 1/? 6. LOSS? COMMENT 1.? (, ) 2. CHECK? 1 CHECK COMMENT : : = X5+ X4+ X3+ X2+ X1, : :
T PM ST EP T EAM M.Hr.
T PM ONE POINT LESSON : : : : : : PLC () () :
T PM ( )ST EP 19 : : ( )
T PM ( ) ST EP ( ) T EAM T EAM MODEL MAN.HOUR T PM COMMENT
T PM MANUAL ST EP P A G E 0 ST EP 1 2 1 ST EP 3 5 2 ST EP. 6 8 3 ST EP.. 9 10 4 ST EP 11 12 5 ST EP 13 6 ST EP 14 7 ST EP 15
< > 1. 1). (1) (2) (3). (4) (5) 2). (1) (2),.., 2. 1) = (,, ) 0 2), Skill
3. 1,, 2, 3,,, (, ) 4 5 6 * * *, * 7, MT BF,
4. 6KEYW ORD 1) (1) -. 3. Model Model Model Model., Know - How. (2). 2) Model. 3),. 4). Model Model Model, Model 5). (One Point Lesson ) 6).
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1. (MEET ING),,,.,. (),., AIR,, MAIN (). 2. (RULE) AIR (),,,,,,,. (, ) 3..,, SHEET. ( ), AIR,,
4. (MEET ING) CHECK SHEET, (, ),, (,,, ) (,,,, ) - T PM ONE POINT 5. FOLLOW,, 2,
C- A- P- D- C- A 1. POINT,,,, ( ),,,, POINT,,,,,, 2ST EP"POINT 2. ST EP ST EP,, / OPERAT OR / /
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,. P M T P M ( T otal P roductiv e M ainte nance : ), (T O P : ) P M,.
(,, ) 3 5 0
(PM) () () ( ) ( ) T P M... 1. () 2. 3.,, 4. 1 5., PM. - JIPE( ) TPMPM T PMPM() PM PM, PM.
INPUT & OUTPUT Max Output Min Input Input : LCC Output P Q C D S M Good P Q C D S M Min LCC InputOutput PM + T PM
TPM T PM,,,,,,,. TPM DOWN,, /,, Operator,,,,,,,, T PM T PM T OP1
TPM PMT PM(T roductive Maintenance) (1) (), (2),, PM, (3),,, (4) (5) PM TPM. T PMT PM.,, PMPM. PMPM PM..
PM.,,,,,, 6(Loss zero). 6,..
T PM - :... : : C/T
( ), ( ), ()3,.,,,.,, 3., ( )..,.
:, 5 (,, )...,. (PM).,.,. (), ( ).
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(CM), CM..,. TBM (Time Bas e d Maintenance ) T BM,,. CBM (Condition Bas ed Maintenance ). (Pre dictive Mainte nance ) Condition Based Maintenance. (Mainte nance of Quality).,.
(Bre ak- Down Mainte nance ),. (MP) PM (), (), MP.,, ( )..
TPM Loss
TQC QC, T P M, =, T P M
TPM 1. T PMT PM : 2. T PM : 3. T PM 4. T PMBenchmark 5. T PM master plan PM 6. T PMkick off 7. 7.1 7.2, 7.3,, 7.4, 8. MP, 9. 10.,, 11.,,, T PM 12. T PM Level- up
,., (+) Zero Zero
,. (,, )...,.
MT BF () PM
. ( ). - ( ) = =..? - (, ) - (,, ) - (,, ) ) 8480, 20 20 460. ( ),.
( )?, (), (),,,,,,, (). ) 460, 20, 20, 20, 60 400.... 400 = = 100 = 87% 460 87%. 87%..,., 20, 60,. (5, 10)
. 30 10 20,. T PM.. 6 (,,,,, ),,,..
()., (, ). ( ). (SPEED DOWN). = () ) () 10.5, 10.8. 0.5 = 100 = 62.5% 0.8 () = = ) 400, 1 0.8, 400. () = 400 0.8 400 100 = 80%
(1- ) 20%. = ( ) = = = TPM.. =
TPM - 90% - 95% - 99% 50% TPM 85% 35%. 50%35%35%50% 7...
6(LOS S ) 6,.,,.. ( )
6 1.. 2., 10 3.. 4.. PPM (100 5. - 300PPM) 6.
A480. NM, B 10, 15. 30 151 SET UP 30. 500 95%. 0.6. 2.5. NMB 1) 2) 3).
= 480 = 10+ 15= 25 = 480-25= 455 = + Set up = 15+ 30= 45 = 455-45= 410 = 500 = 95% = 0.6/ = 1 2.5= 0.4/ = = 410455100 = 90.1% = = 0.4 0.6 100 = 66.7% = ( ) = (500 0.6) 410 100 = 73.2% = = 0.667 0.732 = 48.8% = = 500 0.4 410 100 = 48.8% = = 0.901 0.488 0.95 = 41.8%