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42問 • 2年前

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is a step by step approach for identifying all possible failures in a design a manufacturing or assembly process or a product or services it's a common process analysis tool

failure mode and effects analysis

different types of fmea analysis

functional, concept design/hardware, detailed design, process

before design solution are provided function can be evaluated on potential functional failures effect general mitigation can be proposed to lime consequences of functional figures are lime the probability of occurrence in this early development it is a base functional breakdown of a system this type may be used or software

functional

analysis of system of subsystem in the early design concept stages to analyze the failure mechanism and lower level functional failures especially to different concept collision and more detailed may be used in a trade of studies

concept design

called piece part or hardware and used to identify any possible hardware failure mode off to the lowest part level it should be based on hardware breakdown any failure effects sovereignty failure prevention failure detection and diagnosis may be fully analyzed in this fmea

detailed design

analysis of manufacturing and assembly processes both quality and reliability may be affected from processed fault the input of this fmea among others are work process task breakdown

process

entity is defined the probability that it will perform its intended function for a specified period of time under the stated operating conditions is a measure of the ability of a product to function as extended at given time

reliability

is a graph of failure rate over time

bathtub curve

region 1 region 2

infant mortality failure region, useful life period of the product / constant failure region, wear-out period

probability density function two types of random variables

continuous, discrete

the is a measure of tendency of a product failure if the value of the blank function is high then the probability of failure will be greater

hazard function

is a modern paintings strategy aim at more profits ppm brings mental and focus as a necessary and vitally import part of the business is a maintenance philosophy designed to integrate equipment maintenance into the manufacturing process

total productive maintenance

is a set of maintenance action that are required to be carried out by train employees to prevent failures and increase the life of the equipment

preventive maintenance

it is classified into two types maintenance

periodic maintenance and predictive maintenance

makes the prediction of the equipment failure using date and statistic the life of the equipment are subsystem are determined or predicted based on the current status as the is revealed by an inspection or diagnosed using special tools its condition based maintenance

predictive maintenance

➢ Global automotive component manufacturer. ➢ First Organization to introduce plant wide preventive maintenance (1960’s) ➢ 25% of the company is owned by Toyota motors

NIPPON DENSO

existing elements of TPS were:

• Total Quality Control (TQC) • Just In Time (JIT) • Total Employees Involvement (TEI)

➢ A Japanese citizen and pioneering founder of the Total Productive Maintenance (TPM)

SEIICHE NAKAJIMA

is an indicator of reliability of a product. The unit of MBTF is hours. Higher the MBTF means better reliability.

Mean Time Between Failures(MTBF)

is a measure of maintainability. The average time to repair an item when it becomes defective.

Mean Time to Repair(MTTR)

• Dependability of an equipment depends as ARM.

A-Availability R-Reliability M-Maintainability

is the proportion of time the machine is available for use out of the total time available

Availability

is the ratio of actual production time achieved to the total production time possible.

Rate Efficiency(RE)

Due to many reasons the machine operates at lower speed affecting the production.

Speed Efficiency(SE

2 FACTORS of PERFORMANCE EFFICIENCY (Performance Efficiency(Pe) PE=RE x SE)

Rate Efficiency(RE Speed Efficiency(SE)

Number of good parts produced / Total produced

The quality rate(Q)

OVERALL EQUIPMENT EFFICIENCY(OOE) is determined by 3 factors as given below.

1. Availability (A) 2. Performance Efficiency (PE) 3. Quality Rate (Q)

The portion of the OEE metric that represents the percentage of scheduled time that the operation is available to operate. Often referred to as .

Uptime

Availability is a pure measurement of Uptime that is designed to exclude the effects of Quality and Performance. The losses due to wasted availability are called

availability losses

The 8 Pillars of TPM

Pillar 1-5S Pillar 2 Jishu Hozen (Autonomous Maintenance) JHAM Pillar 3 Kobetsu Kaizen Pillar 4 Planned Maintenance Pillar Quality Maintenance Pillar 6 Training Pillar 7- Office TPM Pillar 8 Safety Health and Environment

Pillar 1 - 5S

1. Sort 2. Set in Order 3. Shine 4. Standardize 5. Sustain

Organization should enable the operators to take responsibility for routine maintenance tasks.

Pillar 2 - Jishu Hozen ( Autonomous Maintenance) JHAM

Steps in JHAM

1. Train the employees. 2. Initial cleanup of machines. 3. Take counter measures 4. Fix tentative JH standards 5. General inspection 6. Autonomous inspection 7. Standardization and 8. Autonomous management

Pillar 3 - Kobetsu Kaizen Three categories loses in organization

1. Loses that impede equipment efficiency 2. Loses that impede human work efficiency 3. Loses that impede use of productresources

Pillar 4 – Planned Maintenance Aimed to planned maintenance such as periodic maintenance and predictive maintenance to enable the following ;

1. Zero equipment breakdown 2. Improve reliability and maintainability of equipment 3. Reduce maintenance cost 4. Ensure availability of spears at all times

this focused in the equipment that will be used to produce quality products And

Pillar 5- Quality maintenance

Pillar 5- Quality maintenance – this focused in the equipment that will be used to produce quality products And it aims for the following:

1. Defect free conditions and control of equipment. 2. Provide support to quality assurance. 3. Focus on prevention of defects at source. 4. Focus on poka-yoke. 5. In-line detection and segregation of defects. 6. Effective implementation of operator quality assurance.

this focused in the equipment that will be used to produce quality products And it aims for the following:

Pillar 5- Quality maintenance

Focuses on improvement of knowledge, skills an techniques of the multi-skilled revitalized work force

Pillar 6- Training

Pillar 7 - Office TPM – a set of maintenance actions that are required to be carried out by trained employees to prevent failures and increase the life of the equipments. TPM aims to eliminate the following:

1. Processing los 2. Cost loss in including areas such as procurement, accounts, marketing, and sales leading to high inventories 3. Communication losss 4. Idle loss 5. Set-up loss 6. Accuracy loss 7. Office equipment breakdown 8. Communication channel breakdown, telephone and fax lines 9. Time spent on retrieval of information 10. Non availability of correct on-line stock status 11. Customer complaints due to logistics 12. Expenses on emergency dispatches/purchases

– a set of maintenance actions that are required to be carried out by trained employees to prevent failures and increase the life of the equipments.

Pillar 7 - Office TPM

This should enable zero accident, zero health problems and zero fire accidents

Pillar 8 - Safety Health and Environment

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Jennie Rose Carpo · 24問 · 2年前

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