中文摘要

由各項研究與實務顯示6σ與TPM是國內外企業常用來強化、改善、改革經營績效之有效流程改善手法;然常見企業在競爭激烈的經營環境中為追求成長及利潤,相繼或同時導入諸多系統及管理改善手法, 未予融合及消化,反致員工無所適從、工作負荷增加及成效不彰。

TPM&6σ主要目的及改善著眼點:
□TPM源於日本電裝,以職制組織、現物確認方式、降低Loss、追求綜合稼動率(OEE: Overall Equipment Efficiency)。
□6σ源於美國Motorola,以專案組織、統計技術、降低變異、追求3.4PPM(百萬分之3.4)品質水準。

諸多研究分別探討如何實行此兩大改善手法,然其整合探討並不多見。企業在有限資源下,如能擷取各手法所長、整合活用於持續改善,進而著實地產出成效,乃是今後企業長期競爭之成功要因及利器。謹以此為目的,參照相關美、日、韓大型企業推展改善之成功經驗,並秉持ISO-8.5.1持續改善之精神, 將六標準差應用在TPM全面生産保全活動,以達整合及產生synergy成效。

本研究以PCB產業「重負荷精密刷磨機」為實例,活用6σ DMAIC及TPM之手法,掌握及管制其關鍵品質特性「振動」之影響要因，以CBM狀態監控保全方式降低故障率及成本,提昇設備之可用度。

研究架構:現物確認(現象)+統計解析(數據)+改善過程DMAIC

Abstract

Many enterprises have introduced and applied Six Sigma & TPM.

Six Sigma is considered the primier methodology through project for improving buisness performance.And TPM is described as “Productive Maintenance” carried out by all employees through small group activities to improve productivity. However, little has been written to date on the application of Six Sigma to plant maintenance.

The term “Total Productive Maintenance” was first used in the late 1960’s by Nippondenso, a supplier of electrical parts to Toyota. At the Time it was a slogan for their plant improvement theme “Productivity Maintenance with total employee participation”. In 1971, and received the The PM Prize from JIPM. Nippondenso was the first plant to receive the award as a result of implementing TPM.

Six Sigma quality initiatives have been popular since being introduced by Motorola in the 1980s and embraced by General Electric in the 1990s. Texts and papers abound on the “What is & How to” of Six Sigma, and training & certification courses are plentiful. However, much of the focus of Six Sigma to date has been on improving the efficiency and cost effectiveness of overall supply chain. Little attention has been paid to the maintenance process.

This paper will provide an overview of Six Sigma methodolgy, as well as TPM methods, and show how Six Sigma methods can be used to optimize and improve maintenance processes. And utilizes the five steps methodolgy to describe and detail the Six Sigma method as applied to maintenance mangement. The five steps are are DMAIC - Define, Measure, Analyze, Improve and Control.

參考文獻
[1]中嶋清一(1992),『生産革新のための新TPM入門』, 日本プラントメンテナンス協会。
[2] 圓川隆夫(2001)東京工業大学大学院教授社会理工学研究科長,「TPMの意義と課題」,日本プラントメンテナンス協会編 『トップが語るTPMと経営戦略』,日本プラントメンテナンス協会。
[3]日本プラントメンテナンス協会編(2002)：『21世紀First AgeのTPM潮流』,日本プラントメンテナンス協会。
[4]日本プラントメンテナンス協会 PM賞運営委員会(2008)
TPM優秀賞審査基準2008年版(制定：2008年8月1日,発行：2008年8月1日)
[5] 長圓川隆夫(2004)東京工業大学大学院教授社会理工学研究科
連載TQM周辺管理技術の今,そしてこれから,第2回TPMとその最近の動向
[6]NPO法人日本保全学会(2006), 保全プログラムと検査に関する検討,資料-1。
[7]制御システム専門委員会(2008),予知保全技術に関する調査報告書, ～21世紀のプラントの安心・安全操業の実現のために～
[8]凌元錦，真木紘一，遊佐訓孝，宮健三(2007), TBMとCBMを併用した保全方式におけるTBM実施間隔最適化モデルの開発,日本原子力学会和文論文誌，Vol. 6, No. 3, p. 312319 (2007)。
[9]坂出事業所(2007),坂出事業所のTPM活動,TAKADA TECHNICAL REPORT
Vol.17 2007。
[10] Hrgarek Nadica & Bowers Kerri-Anne (2009), Integrating Six Sigma into a Quality Management System in the Medical Device Industry,
JIOS.VOL. 33, NO. 1 ,2009 。
[11] Thomas A.J. & G.R. Vidales Jones& P. Manufacturing Engineering Centre, Cardiff University, CF24 3AA, UK, Wall Colmonoy, Pontardawe, Swansea, SA1 3DE -Ecole d'ingeniear CESI, France
An Integrated Approach to TPM and Six Sigma Development in the Castings Industry。

[12]JIPM主幹研究員水越興三郎(2007),TPM活動の評價指標に關する研究報告
Plant Engineer, Jun 2007。
[13] Thomas R. Pomorski(2004),Principal Consulting Engineer,Brooks Automation, Inc., Total Productive Maintenance (TPM)Concepts and Literature Review, Total Productive Maintenance Concepts and Literature Review April 30, 2004。
[14]日本プラントメンテナンス協会(2008),
2008年度「メンテナンス實態調查」の概要。
[15]James E. Brady & Theodore T. Allen.,The Ohio State University & System Engineering,Six Sigma Literature: A Review and Agenda for Future Reserch.
[16] Kevin D. Creehan (2005),Center for High Performance Manufacturing Grado Department of Industrial and Systems Engineering (0118)
Virginia Polytechnic Institute and State University, ESTABLISHING OPTIMAL MAINTENANCE PRACTICES IN A TRADITIONAL MANUFACTURING ENVIRONMENT, Journal of the Chinese Institute of Industrial Engineers, Vol. 22, No. 1, pp. 11-18 (2005)
[17] Pedja Milosavljević, Klaus Rall, Technical University Hamburg-Harburg
Department for Machine Tools and Automation Technology Denickestrasse 17, 21073 Hamburg, Germany,SIX SIGMA CONCEPT IN THE MAINTENANCE PROCESS OF TECHNICAL SYSTEMS, Mechanical Engineering Vol. 3, No 1, 2005, pp. 93 - 108
[18] Kahn Jerry D. (2006), PE, CMRP Principal Consultant JK Consulting
Fayetteville, Georgia USA, Applying Six Sigma to Plant Maintenance Improvement Programs,
[19] Asian Productivity Organization (2003), Six Sigma for Quality and Productivity Promotion, Productivity Series 32。
[20] Ress Jay, Principal (2003) - Technology Management Associates,
The Intersection between Project Management and Six sigma。
[21] Huesing Tina, Motorola (2008), Six Sigma Through the Years ,
[22] Kennedy Ross (2009),CTPM Australasia,TPM & Six Sigma Similarities and Difference,CTPM Technical Paper。
[22]JMAC (2007),TPM through LEAN Methodollogy ,JMAC America, Inc.
[23] Osten David (2002), Applying Six Sigma at 3M。
[24]Edson Silveira de Oliveira(2004),Dupond Six Sigma Program。
[25] Mughal M. A., Saeed N. & Pervaiz M. K. (2009) Government College University, Lahore, Pakistan, Six Sigma Methodology as a Problem Solving Technique, Journal of Quality and Technology Management Volume V, Issue I1, Dec, 2009, pg. 51-61。
[26] Lee Morris Mau-Hsin (2008), Corporate Synergy Development Center,
The Important FactorsInfluencing the Result of Implementing TPM, APIEM International Conference, 2008/3/25。
[27]TOSHIBA ELECTONIC ENGINEERING CORPORATION(2007), メカトロル技術,綜合稼動率計算。
[30] GE網站,The Roadmap to Customer Impact
[31]森田洋男(2008),Process改善の真髓,Sony Grobal Solution.Inc.