Để thực hiện TPM cần 12 bước, được chia thành 4 giai đoạn:
1. Giai đoạn chuẩn bị.
2. Giai đoạn giới thiệu.
3. Giai đoạn thực hiện.
4. Giai đoạn củng cố.
Giai đoạn chuẩn bị : từ 3 đến 6 tháng, gồm các bước:
Bước 1 : Lãnh đạo cao nhất giới thiệu TPM.
Bước 2 : Đào tạo và giới thiệu TPM.
Bước 3 : Hoạch định các tổ chức tiến hành thực hiện TPM.
Bước 4: Thiết lập các chính sách cơ bản và các mục tiêu của TPM.
Bước 5: Trình bày kế hoạch phát triển TPM.
Giai đoạn giới thiệu TPM :
Bước 6: Bắt đầu TPM (hoạch định và thực hiện).
Giai đoạn thực hiện:Bước 7: Cải tiến hiệu suất của mỗi thiết bị trong dây chuyền sản xuất.
ª Xác định rõ công việc.
ª Xem xét tình trạng máy móc.
ª Xem xét mối quan hệ giữa máy móc, thiết bị, vật tư và các phương pháp sản xuất.
ª Xem xét trình tự đánh giá chung.
ª Xác định cụ thể các vấn đề.
ª Đề xuất các cải tiến phù hợp.
Bước 8: Tổ chức công việc bảo trì.
ª Chuẩn bị.
ª Đo lường, kiểm tra dựa vào các nguyên nhân.
ª Thiết lập tiêu chuẩn làm sạch và bôi trơn.
ª Kiểm tra tổng thể.
ª Kiểm tra việc tự quản.
ª Đảm bảo tính ngăn nắp và gọn gàng.
ª Tự quản lý hoàn toàn.
Bước 9: Thực hiện công việc bảo trì có kế hoạch trong bộ phận bảo trì.
Bước 10: Đào tạo để nâng cao các kỹ năng bảo trì và vận hành.
Bước 11: Tổ chức công việc quản lý thiết bị.
Giai đoạn củng cố:
Bước 12: Thực hiện hoàn chỉnh TPM ở mức độ cao hơn.
9. Lean TPM
Lean và TPM được kết hợp để hình thành Lean TPM.
Lean TPM nếu được thực hiện đúng, không chỉ mang lại hiệu quả mà còn làm tăng năng suất và giảm các loại lãng phí.
Lean TPM đòi hỏi một tổ chức tập trung vào các chức năng bảo trì và kỹ thuật để cải thiện thời gian máy chạy, khả năng sẵ khả năng sẵn sàng và chát lượng. Làm được như vậy các đội bảo trì được tăng cường tri thức về thiết bị đồng thời phát triển mối quan hệ thân thiện và tích cực giữa họ với nhau và với các bộ phận khác trong doanh nghiệp.
Mục tiêu của Lean TPM là hình thành một đội ngũ bảo trì tạo ra giá trị gia tăng mà không làm tăng chi phí trong phạm vi doanh nghiệp.
Phần lớn doanh nghiệp đều biết nhưng không thể hiểu đến nơi đến chốn các thiệt hại ẩn gây ra do ngừng máy, những lần gián đoạn sản xuất để thay đổi đồ gá hoặc điều chỉnh máy, tốc độ máy bị giảm, máy chạy không hoặc ngừng vài phút, khởi động lại, sản phẩm khuyết tật và công việc tái chế.
Vì vậy nguyên tắc chính của một chương trình lean TPM là hiểu, định lượng và tiến hành làm giảm đến mức tối thiểu hậu quả của những thiệt hại nêu trên.
10. Thực hiện Lean TPM
Mức 1: Ổn định hóa
@ Mức 1A: Kiểm soát
– Phân tích tình trạng hiện thời của thiết bị. Làm vệ sinh toàn bộ khu vực sản xuất.
– Hoàn thành việc đánh giá và xác định tầm nhìn, mục tiêu.
– Bắt đầu ghi nhận các chỉ số hiệu năng của thiết bị và nhận dạng tiềm năng cải thiện.
@ Mức 1B: Ổn định hóa
– Thực hiện kế hoạch bảo trì hàng năm và phát triển thêm chương trình bảo trì có kế hoạch.
– Xác định lộ trình cải tiến và phân công trách nhiệm cải tiến các tiêu chuẩn, định mức.
– Khẳng định tầm nhìn và mục tiêu. Lập tài liệu và truyền thông cho mọi người có liên quan.
– Bắt đầu thực hiện các qui trình bảo trì phòng ngừa.
Mức 2: Tối ưu hóa
Mức 2A: Tinh gọn từ thực tế
– Phát triển chương trình để tăng mức độ bảo trì trên cơ sở tình trạng.
– Cải thiện môi trường vận hành thiết bị.
– Phấn đấu giảm số lần hư hỏng máy.
Mức 2B: Nhắm mục tiêu số hư hỏng bằng không
Phát triển một chương trìnhbảo trì chất lượng nhằm đạt mục tiêu số hư hỏng máy và số sản phẩm khuyết tật bằng không.
11. Kết luận
TPM và Lean TPM còn rất xa lạ với đa số các doanh nghiệp sản xuất công nghiệp Việt Nam trong khi bảo trì vẫn là công việc hàng ngày phải làm. Vì mục tiêu giảm thiệt hại tối đa do ngừng máy, đã đến lúc các doanh nghiệp cần tăng tốc trong việc áp dụng các hệ thống quản lý bảo trì tiên tiến mà TPM có thể là mục tiêu trước mắt.
Tài liệu tham khảo
[1] Phạm Ngọc Tuấn, Quản lý bảo trì công nghiệp, NXB Đại học Quốc gia TPHCM, 2001, 172 tr.
[2] Phạm Ngọc Tuấn, Kỹ thuật bảo trì công nghiệp, NXB Đại học Quốc gia TPHCM, 2005, 197 tr.
[3] Dennis McCarthy, Nick Rich, Lean TPM, A Blueprint for Change, Elsevier Butterworth-Heinemann, 212p.
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