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MCK-KCI精益運(yùn)營(yíng)項(xiàng)目_設(shè)備全局效率OEE1

Tableofcontent

內(nèi)容1Learningobjective&TOC

學(xué)習(xí)目的和內(nèi)容WhatisOEE?

什么是OEELinkingOEEtoPerformance

鏈接OEE到績(jī)效IntroductionofOEEprogram

介紹OEE程序Conclusion

結(jié)論3-14

16-2123-2426ExplainthepurposeofdeterminingOverallEquipmentEffectiveness(OEE)

解釋OEE的目的UnderstandhowOEEhelpsdriveperformanceaspart

ofaleanproductionsystem

了解精益生產(chǎn)系統(tǒng)中OEE如何幫助績(jī)效改善Attheendofthissessionyouwillbeableto

本節(jié)學(xué)習(xí)完你將會(huì)PageLearningobjective

學(xué)習(xí)目的2

2Agenda

OverallEquipmentEffectiveness(OEE)WhatisOEE?

什么是OEELinkingOEEtoPerformance

鏈接OEE到績(jī)效IntroductionofOEEprogram

介紹OEE程序Conclusion

結(jié)論3

3WhatisOEE?

什么是OEEDefinition:Ashopfloortooltomeasurehowwellmanufacturing

equipmentisrunningwhencomparedtothetheoreticalgoal定義：用來(lái)跟理論產(chǎn)值比較以評(píng)估生產(chǎn)設(shè)備的運(yùn)作效率的現(xiàn)場(chǎng)工具Theuseof

OEEiscriticaltosupportingtheleantooldeploymentOEE的運(yùn)用對(duì)于支持精益工具開(kāi)展具有重要意義CellDesignMaterialReplenishment&FlowSixSigmaQuickChangeOver(QCO)VoiceoftheCustomer(VOC)TotalProductiveMaintenance(TPM)ProductionPreparationProcess(3P)MistakeProofingStandardWorkVisualFactoryQualityControlProcessCharts(QCPC)5SValueStreamMapping4

3WhyisOEE?為什么是OEE？OEEtakesthemostcommonandimportantsourcesofproductivitylosses,andplacestheminto3categoriesOEE涉及的是生產(chǎn)最常見(jiàn)最重要的損失來(lái)源，并將它們劃分為3類(lèi)Availability–anylossthatstopsplannedproduction

時(shí)間利用率-導(dǎo)致計(jì)劃生產(chǎn)停止的任何損失Performance–anylossthatcausesplannedproductiontooperateatlessthanmaximumpossiblespeed

設(shè)備性能率-導(dǎo)致計(jì)劃生產(chǎn)以低于最大可能速度進(jìn)行的損失

Quality–anylossarisingfromproducedpartsthatdonotmeetqualitystandards

品質(zhì)合格率-導(dǎo)致產(chǎn)品不符合質(zhì)量標(biāo)準(zhǔn)的損失OEEgivesustheoverallpictureofmachineperformance,notfocusingjustonefficiencyorutilizationOEE給我們呈現(xiàn)的是機(jī)器效能整體狀況，而不是只專注于效率或利用率OEEismeasuredatamachinelevelOEE是用來(lái)測(cè)量機(jī)器的AmeasureofTruecapacityofprocess機(jī)器真實(shí)產(chǎn)能的衡量Prioritizedwaytoeliminatelossesofprocess消除流程損失的優(yōu)先方式5

OEEbreakdown

OEE分類(lèi)TotalShiftTime(24hrsx365days)返時(shí)間(24小時(shí)X365天)OEE

Losses6BigOEELossesAvailableProductionTime可利用時(shí)間EffectiveTime創(chuàng)造價(jià)值的時(shí)間Takingproductivitylossesintoaccount,effectiveproductiontime

(timethatgoodpartsareproduced)isonlyafractionofwhatisavailable將產(chǎn)能損失分成不同的項(xiàng)，有效的生產(chǎn)時(shí)間(生產(chǎn)出好產(chǎn)品的時(shí)間)

只是總可利用時(shí)間的一部分PlannedStops計(jì)劃停機(jī)時(shí)間Availabilitylosses停機(jī)損失Performancelosses性能損失Qualitylosses質(zhì)量損失Scrap廢品Rework

返工MinorStops小停機(jī)ReducedSpeed降速Breakdowns

故障停機(jī)Changeovers換型6

ThesixbigOEElosses

六類(lèi)主要OEE損失Loss損失Category種類(lèi)Description描述EventExamples舉例Breakdowns故障Availability時(shí)間利用率Machinestopduetoatechnicalproblemordamage由于技術(shù)或者損壞所導(dǎo)致的停機(jī)Duration>15minutes停機(jī)達(dá)15分鐘以上Requiresrepairtofix需要修理以解決Changeovers換型Availability時(shí)間利用率Stopsinproductionduetomaterialortoolingchanges原材料或者工具的改變導(dǎo)致的生產(chǎn)中停機(jī)MinorStops小停機(jī)Performance設(shè)備性能率Machinestopduetoprocessproblem

工藝問(wèn)題導(dǎo)致的停機(jī)Norepairofcomponentsrequired,afterprocessadjustmentsandcleanup

經(jīng)過(guò)工藝調(diào)整或者情急，無(wú)需修理Machineisrunningagain<<15min

少于（或者等于15mins）可再開(kāi)機(jī)ReducedSpeed降速Performance設(shè)備性能率Actuallinespeedsthatfallbelowratings低于目標(biāo)速度的實(shí)際速度Scrap廢品Quality品質(zhì)合格率Defectivepartsproducedduringnormaloperations正常操作中所生生的不合格品Rework

返工Quality品質(zhì)合格率Partsthatfailinspection,butcanbefixedtomeetspecifications產(chǎn)品未通過(guò)檢驗(yàn)，但可經(jīng)過(guò)修復(fù)滿足標(biāo)準(zhǔn)1456Unplannedmaintenance非計(jì)劃維修Equipmentfailures設(shè)備故障Shiftingthelinefrom

PartAtoPartB產(chǎn)品A換到產(chǎn)品BJammedcomponents

產(chǎn)品堵CleaningorChecking

清潔或者檢查Equipmentwear

設(shè)備磨損Operatoradjustments

操作工調(diào)整In-processdamage

過(guò)程中的損壞Badmaterialinputs

不良原材料導(dǎo)入Incorrectassembly

錯(cuò)誤的裝配In-processexpiration

過(guò)程中的吹落237

OEE–visualoverviewoflosses損失可視化概述SampleLineOEE,Hour(perweek)This“scheduledtime”measurementisoftencalledOEE2andisthemostpertinentforperformancemeasurementandmanagement“計(jì)劃時(shí)間”測(cè)量通常稱為OEE2，是績(jī)效測(cè)量和管理有效的衡量方式

20OEE148%OEE267%“Thetimethemachineisscheduledtorunduringthemonth”本月內(nèi)機(jī)器計(jì)劃開(kāi)機(jī)時(shí)間Thisleavesuswith120hrsuponwhichtobaseonperformancemeasurements基于設(shè)備性能率測(cè)量方法，這個(gè)時(shí)間是120小時(shí)8

OEE–visualoverviewoflosses損失可視化概述SampleLineOEE,Hour(perweek)

20OEE148%OEE267%“Theremainingtimeafterbreakdownandchangeoversandexternaloutagesareconsidered”除了故障，換型和外部中斷所剩余的時(shí)間AvailabilityLoss時(shí)間利用率損失PerformanceLoss設(shè)備效率損失9

OEE–visualoverviewoflosses損失可視化概述SampleLineOEE,Hour(perweek)

20OEE148%OEE267%“Theremainingtimewhenlossesfromnotfollowingstandardspeedsandminorstopsareconsidered”除去未開(kāi)到標(biāo)準(zhǔn)速度和小停機(jī)剩余的時(shí)間QualityLoss質(zhì)量損失10

OEE–visualoverviewoflosses損失可視化概述SampleLineOEE,Hour(perweek)

20OEE148%OEE267%“Theremainingtimewhenlossesfromscrapareconsidered”除去生產(chǎn)廢品時(shí)間后的剩余時(shí)間OEEcalculationOEE計(jì)算11

OEEAvailabletime可利用時(shí)間Nettime凈利用時(shí)間Time-based時(shí)間為依據(jù)Part-based產(chǎn)品數(shù)量為依據(jù)OEEQuantityofpartsthatshouldtheoreticallybeproduced理論產(chǎn)品數(shù)Quantityofactualgood

partsproduced實(shí)際好產(chǎn)品數(shù)Therearetwo(2)methodsforcalculatingOEE1

計(jì)算OEE1有兩種方法1Dependsupontimeand/orpartdataavailability12

CalculatingOEE–example

計(jì)算OEE-例子Availability0.75OEE =AvailabilityXPerformanceXQualityX100 =0.75X0.60X0.80X100OEE =36%Totalplantoperatingtime=510minutesScheduledProductionTime=

480minutesNoproduction

scheduledOperatingtime=360minutesAvailabilitylossesTargetoutput=1,080partsActualoutput=648partsQualitylossesEActualoutput=

648partsFGoodoutput=518partsPerform.losses0.60ScheduledtimeAvailabletimeTargetoutputActualoutputActualoutputGoodoutput480minutes360minutes1,080parts648parts648parts518parts===0.80===OEEcalculationexamplePerformanceQualityABCD===13

WaterfallchartsareausefulmeansofillustratingtheOEEbreakdownCalculatingOEE–example計(jì)算OEE-例子OperatingtimeChange-overs80.0Break-downsAvailableproduc-tiontimeSched-uledMainte-nanceUnsched-uledProduc-

tionTotalplant

time172.0Effectiveproduc-tiontimeReworkScrapRunningtime216.0ReducedspeedMinor

stops36%OEEAvailabilitylossPerformancelossQualityloss14

PerformancesummaryreportfromOEEOEE績(jī)效總結(jié)報(bào)告ScheduletimeAvailabletimeOperatingtimeNettimeOEE(%)XXXXXXXXXX“Wecanclearlyunderstandwherewe’reanddecidethedirectionforimprovementthroughOEEanalysis”通過(guò)分析OEE，我們可以清楚地知道我們的位置，同時(shí)確定改善的方向15

7Agenda

OverallEquipmentEffectiveness(OEE)WhatisOEE?

什么是OEELinkingOEEtoPerformance

鏈接OEE到績(jī)效IntroductionofOEEprogram

介紹OEE程序Conclusion

結(jié)論16

BenefitsofOEE

OEE的好處ImprovingOEEcanhaveasignificantimpactonbusinessperformance改善OEE對(duì)績(jī)效有顯著的影響Reduce

cost降低成本Impact

影響度Performancemetric

績(jī)效Sourceofimpact

影響源Improvequality質(zhì)量提升Rejects(scrap,rework)

拒收(廢品，返工)First-passyield首件合格率Improvedyields改善良品率Improvedelivery交貨改善Leadtime

交付期Reliable/fasterthroughputrate合理/快速的備貨率On-timedeliverytocustomer(rightquantity,quality,andtime)及時(shí)送貨到客戶(數(shù)量，質(zhì)量，時(shí)間)Reduceddowntimeandscrapcreatesstability,allowingadherencetotheschedule降低停機(jī)時(shí)間及不合格率，創(chuàng)造穩(wěn)定及符合生產(chǎn)排產(chǎn)Inventory庫(kù)存ReducedscrapraterequireslessWIP降低不良品可使白片減少Productivity產(chǎn)量Withlessdowntime,peoplehavemoretimeforValueAddedwork少的停機(jī)，人們有更多的時(shí)間從事增值工作Capex(capitalexpenditures)資本支出Latentcapacityreleased潛在的產(chǎn)能提升17

OEEimprovementtoollevers

OEE改善工具Availability時(shí)間利用率Quality質(zhì)量合格率Improvementapproaches改善方法5SStandard

work標(biāo)準(zhǔn)化工作GOMeetingsGO會(huì)議QCO快速換型TPM全員參與性維護(hù)Breakdowns故障停機(jī)Changeover換型Minorstops小停機(jī)Reducedspeed降速Scrap廢品Rework返工RelevanceLowHighLossCategory損失種類(lèi)Performance設(shè)備性能率18

AddressingthesixbigOEElosses

分析六大OEE損失Breakdowns故障停機(jī)Movingpartsandvariousmachinesubsystemsfail(forexample,conveyorbeltbreaks)運(yùn)動(dòng)部件及各重機(jī)器子系統(tǒng)失效(例如：皮帶斷)Empowerworkerstoperformbasicmaintenancetasks授權(quán)給操作工能完成基本的維修工作Conductplannedmaintenance–bothpreventiveandpredictivemaintenance完成計(jì)劃維修

–包含預(yù)防性和預(yù)知性保養(yǎng)Changeover換型Timerequiredtosetupmachineforadifferentpart需要時(shí)間去設(shè)定機(jī)器的不同部位Cleaningandadjustments清潔和調(diào)整Locatingtools,parts,people工具，備件和人員的定位Startup–defectiveproductsmadewhileworkerstestfor

stableoutput

啟動(dòng)–當(dāng)現(xiàn)場(chǎng)人員測(cè)試穩(wěn)定生產(chǎn)時(shí)產(chǎn)生的不良品EmployQCO(QuickChangeover)toshortenset-uptimes

使用快速換型以縮短設(shè)定時(shí)間Separateinternalandexternal

changeover

分出內(nèi)部工作及外部工作Convertinternalchangeover

toexternal

將內(nèi)部工作轉(zhuǎn)換成外部工作Streamlineallaspectsofchangeover換型活動(dòng)順暢化MechanicalJidoka–designmachineswithmistakeproofingsystemsthatautomaticallycheckconditionsandsignalwhenproblemsoccur

機(jī)械式自動(dòng)化

–設(shè)計(jì)防錯(cuò)法的機(jī)器系統(tǒng)，能自

動(dòng)檢查狀況及指出故障點(diǎn)Losses

損失Solutions

解決方案19

AddressingthesixbigOEElosses

分析六大OEE損失MinorStops小停機(jī)Trackproductionperformance

(forexample,hour-by-hourcharts)

跟蹤生產(chǎn)績(jī)效(例如每小時(shí)的圖示)Conductroot-causeproblemsolvingtodeterminewhethertheproblemisstaff,material,methodormachine

運(yùn)用根本原因問(wèn)題解決辦法，以弄清問(wèn)題是否是人，機(jī)，料，法ImplementQCPCeffectively

有效的推動(dòng)QCPC(過(guò)程品質(zhì)管制圖)ReducedSpeed速度降低Eventsthatinterruptproductionflowwithoutmachinefailure;

forexample,機(jī)器未故障所導(dǎo)致的中斷生產(chǎn)，例如Labeldispenserneedsminorfixorreloading

標(biāo)簽機(jī)需要小的修理或者裝

標(biāo)簽Workerisnotavailabletostartupmachineafter

lunch午餐后人員未到位開(kāi)機(jī)Machinerunsslowerthandesignedtooperate(forexample,apresscapableofcycling10strokesaminuteissetat5strokes)

機(jī)器開(kāi)的比設(shè)計(jì)速度慢(例如一個(gè)沖床每分鐘可沖10次，目前是設(shè)定5次)Losses

損失Solutions

解決方案20

Scrap廢品Mistakeproofingtoeliminatethesourceofdefects

防錯(cuò)法以消除缺陷來(lái)源HumanJidoka(linestop,identifyandcall)–giveworkerstheauthoritytostopthelinewheneveranabnormalityordefectisfound人力自動(dòng)化(生產(chǎn)線停機(jī)，確認(rèn)及請(qǐng)求支援）–授權(quán)現(xiàn)場(chǎng)員工當(dāng)不合格品或是缺陷產(chǎn)品產(chǎn)

出時(shí)，有權(quán)停機(jī)Rework

返工Productsorservicesfailingtomeetestablishedproductionspecificationsorcustomerrequirements產(chǎn)品或是服務(wù)失效，無(wú)法符合既定的生產(chǎn)規(guī)范或是客戶需求Productsthatrequirenon-standardoperationstomeetcustomerspecifications(forexampleproductsdamagedin-processthatrequirerepair)

產(chǎn)品需要透過(guò)不是標(biāo)準(zhǔn)的操作程式以符合客戶規(guī)格(產(chǎn)品過(guò)程中損壞需要修理)AddressingthesixbigOEElosses

分析六大OEE損失Losses

損失Solutions解決方案21

0OEEasameasureofcapacity

OEE作為設(shè)備能力的測(cè)量Futurestate

TaktTime–68.5未來(lái)的節(jié)拍時(shí)間

–68.5Current-state

TaktTime–94.7當(dāng)前的節(jié)拍時(shí)間–94.7Op60Op50Op40Op30Op20Op10WithoutOEEimprovement,aCAPEXinvestmentisrequiredtopurchaseadditionalequipmentandincreasecapacityforOp40Op40未做OEE的改善前，資本的投資以添購(gòu)新設(shè)備增加產(chǎn)能是必需的OEE0.780.700.450.480.770.75EXAMPLEEffectivecycletime1有效的節(jié)拍(seconds)Assessment評(píng)估

Howcanwereducetheeffectivecycletime(forexample,increasecapacity)?如何能減少有效的節(jié)拍（例如：增加產(chǎn)能)？1Effectivecycletime=ObservedCycleTime/OEE

有效的節(jié)拍=當(dāng)前節(jié)拍/OEECycletimeadjustmentduetoOEElosses由于OEE的損失導(dǎo)致節(jié)拍調(diào)整ObservedCycleTime當(dāng)前節(jié)拍22

Agenda

OverallEquipmentEffectiveness(OEE)WhatisOEE?

什么是OEELinkingOEEtoPerformance

鏈接OEE到績(jī)效IntroductionofOEEprogram

介紹OEE程序Conclusion

結(jié)論23

23

OEEprogram–datainputbyoperatorsOEEprogram–reportingbystaffsSOURCE:KCIOSTayuanMillLEANteamCollectmoreaccuratedelaydataatshopfloorStrengthenawarenessofdailyaccountabilitytooperatorsPrioritizelosseasily(e.g.,losstype,detaillossreason)UsemoreeffectivevisualmanagementonperformancedialogueActualoutcomesCollectingsingleminutedelaydat