Triển khai Bảo trì Tự quản(AM) & Bảo trì có Kế hoạch (PM)

1. TPM la gi? 8 Tru cot & Vai tro cua AM, PM

TPM (Total Productive Maintenance – Bao tri Nang suat Toan dien) la he thong bao tri de dam bao hieu suat toi uu cua may moc, thiet bi thong qua su tham gia cua TOAN BO nhan vien (Tu dieu hanh den Giam doc). Muc tieu: Zero Breakdown, Zero Defect, Zero Accident.

8 Tru cot TPM (TPM House):

AM & PM la 2 tru cot “song song” quan trong nhat: AM lam boi Van hanh vien (Operator), PM lam boi Ky su bao tri (Maintainer).

2. Autonomous Maintenance (AM) – Bao tri Tu quan 7 buoc

AM chuyen doi Van hanh vien tu “Nguoi chay may” thanh “Chu so huu may”. 7 Buoc (Step 0-7):

1. Buoc 0: Chuan bi & Dao tao. Dao tao kien thuc co ban ve may, an toan, 5S, kiem tra truc quan.
2. Buoc 1: Lam sach ban dau (Initial Cleaning).
   • Lam sach toan bo may (ngoai, trong, kho kho).
   • Phat hien & Ghi nhan Bat thuong (Abnormalities): Rò rỉ, nứt, lỏng, mòn, nóng bất thường.
   • Dung “Red Tag” de danh dau bat thuong. Khac phuc ngay (Quick fix) hoac chuyen PM.
3. Buoc 2: Loai bo nguon goc Bat thuong & Kho kho lam sach (Containment).
   • Loai bo nguon gay rot ri, ban, bui, nhiet (Root cause elimination).
   • Cai tien “Kho kho lam sach/Kho kho kiem tra”: Lap che day dan, cap nha may, cong goi mo, den LED, rule chu.
   • 5S tai cho may (Seiri, Seiton, Seiso, Seiketsu, Shitsuke).
4. Buoc 3: Lap chuan Bao tri Tu quan (AM Standards).
   • Xac dinh: Kiem tra gi? Kiem tra nhu the nao? Kiem tra luc nao? Ai kiem tra? Tieu chuan la gi?
   • Xay dung “AM Audit Sheet” (Bang kiem tra AM) truc quan: Hinh anh, mau sac, OK/NG.
5. Buoc 4: Kiem tra Chung (General Inspection).
   • Dao tao Van hanh vien kiem tra cac bo phan chuan, dien, y khac, lop.
   • Su dung cong cu kiem tra: Multimeter, Megger, Thermometer, Vibration meter, Stethoscope.
   • Phat hien som su co (Early detection).
6. Buoc 5: Tu quan Quan ly (Autonomous Management).
   • Van hanh vien tu quan ly: Kiem tra, Bo tri nhoi, Dieu chinh, Thay phu lieu tieu hao.
   • Quan ly truc quan: Shadow board, Kamishibai board, Andon.
   • Ky su PM tro thanh “Coach” ho tro, khong lam thay.
7. Buoc 6: He thong Quan ly TPM (TPM Management System).
   • Tich hop AM vao he thong quan ly chat luong ISO 9001, IATF 16949.
   • KPIs: AM Compliance Rate, So luong Bat thuong phat hien, MTBF tang, MTTR giam.
   • Cai tien lien tuc (Kaizen) tren co so AM.

3. Planned Maintenance (PM) – Bao tri co Ke hoach

PM chuyen doi tu “Bao tri phan ung (Reactive/Breakdown)” sang “Bao tri phong ngua & Du bao (Preventive & Predictive)”.

4 Giai doan phat trien PM (PM Maturity Model):

1. Giai doan 1: Breakdown Maintenance (BM). Hong moi sua. Chi phi cao, Downtime dai, Khong the du bao.
2. Giai doan 2: Preventive Maintenance (Time-based). Bao tri dinh ky theo thoi gian (Tuan/Thang). Giam Breakdown nhung van co “Over-maintenance” (Sua may van tot) hoac “Under-maintenance” (Van hong giua ky).
3. Giai doan 3: Predictive Maintenance (Condition-based – CBM). Giam sat dieu kien may (Dynamic, Oil, Thermal, Electrical). Sua CHUAN khi can. Can cong nghe: Vibration Analysis, Oil Analysis, Thermography, Motor Current Signature Analysis (MCSA).
4. Giai doan 4: Precision Maintenance & Maintenance Prevention (MP). Bao tri chuan xac (Alignment, Balancing, Torque). Thiet ke may moi khong can bao tri (MP Design).

Cac loai PM:

• Daily PM: Kiem tra truc quan, nhiet do, rung, am thanh, mau sac (Lam boi Operator/AM).
• Periodic PM (Weekly/Monthly/Quarterly/Yearly): Bo tri, ve sinh, kiem tra, thay the phu lieu (Filter, Belt, Oil, Bearing) theo Lich PM.
• Predictive PM (CBM): Giam sat dieu kien: Vibration, Oil, Thermography, Ultrasound, MCSA.
• Overhaul (Dai tu): Tho lap, kiem tra toan bo, sua chuc dia, chuan hoa lai may.

Quy trinh PM hieu qua:

1. Equipment Criticality Analysis (ABC Analysis): Phan loai may A (Critical), B (Important), C (General).
2. FMEA cho Thiet bi (Equipment FMEA): Xac dinh Che do that bai (Failure Modes), Nguyen nhan, Tac dong. -> Xay dung PM Task List.
3. Xay dung Lich PM (PM Schedule) & Checklist: Chu ky, Noi dung, Tieu chuan, Nguoi thuc hien, Cong cu.
4. Thuc hien & Ghi nhan (CMMS/EAM): Su dung phan mem quan ly bao tri (CMMS) de lap lenh, ghi nhan, lich su, Bao cao.
5. Phan tich & Cai tien (PDCA): Phan tich MTBF, MTTR, Downtime, Chi phi. Cai tien Lich PM, Chu ky, Ky thuat.

4. Chi so quan trong: MTBF, MTTR, OEE, Availability

5. Quy trinh trien khai AM & PM tai Gemba

1. Khoi dong: Cam ket Lanh dao, Thiet lap Ban chi dao TPM, Chon Pilot Area (Model Line).
2. Dao tao: Dao tao TPM Overview, AM 7 buoc, PM FMEA, CBM, 5S, An toan cho Pilot Team.
3. AM Pilot (Buoc 0-3): Lam sach, Loai bo nguon bat thuong, Lap chuan AM. Thoi gian: 3-6 thang.
4. PM Pilot: ABC Analysis, Equipment FMEA, Xay dung PM Task List, Lich PM, Trien khai CMMS.
5. Mo rong (Roll-out): Mo rong sang cac dong chuyen, nha khac. Chuan hoa tai lieu, Dao tao ToT (Training of Trainers).
6. Dung hanh & Chuan hoa: Tich hop vao he thong quan ly (ISO/IATF). KPIs: AM Compliance, PM Compliance, MTBF, MTTR, OEE.

6. Case study

• Vinamilk (Sua): Trien khai AM 7 buoc tren 50+ dong chuyen. MTBF tang 300%, MTTR giam 50%. OEE tu 65% len 88%. Nhan vien AM phat hien 5000+ bat thuong/nam.
• Thaco (O to): Ket hop AM (Operator) + PM (Ky su) + CBM (Vibration, Oil). Giam Downtime 40%. Chuyen tu BM -> Predictive PM tren cac may CNC, Press.
• Samsung (Dien thoai): AM & PM chuan Toyota. “Zero Breakdown” tren dong SMT, Injection. Su dung CMMS quan ly 10,000+ thiet bi.
• CiCC Client (SME Nhua, 50 may): Tu BM (Hong moi sua) -> PM dinh ky + AM. Dau tu CMMS thap chi phi. KQ: Downtime giam tu 15% -> 3% trong 1 nam. Tiet kiem 500 trieu dong/nm chi phi sua chua.

7. Template & Tool cung cap

1. AM 7-Step Implementation Roadmap (Excel/Gantt)
2. Red Tag Register & Tracking Sheet (Excel)
3. AM Audit Checklist (Excel – Hinh anh, OK/NG, Tan suat)
4. Equipment Criticality Analysis (ABC) Template (Excel)
5. Equipment FMEA Template (Excel – AIAG FMEA Format)
6. PM Task List & Schedule Template (Excel – Daily, Weekly, Monthly, Yearly)
7. CBM Data Collection & Trend Analysis Sheet (Excel)
8. MTBF/MTTR/OEE Calculator & Dashboard (Excel)
9. CMMS Selection & Requirements Checklist (Excel)
10. TPM Maturity Self-Assessment (Excel)

8. Lien he

Hotline: 098 905 1920 (Chi Dung)

Email: dung.truong@lean.vn

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