精益生产-设备利用率.ppt

The Six Big Equipment Losses 设备的六大损失,The Six Big Equipment Losses 设备的六大损失,Breakdowns故障停工 Set-up and adjustments架模和调整 Idling and minor stoppages闲置(空转)和不严重的中断 Speed losses无法全速运转 Start-up/yield losses (reduced yield between machine start-up and stable production)起动/生产损失(机器起动到稳定生产之间的产量缩减) Quality defects and rework报废和重工,The Six Big Equipment Losses 设备的六大损失,Breakdowns故障停工 The time that is lost for production due to equipment failures.由于机器故障而损失了生产时间 How many hours a month is lost due to breakdowns?每个月因机器故障而损失了多少小时? Is it normal to fight the breakdown fires? 紧急处理机器故障是属于正常的情况吗? How often do we have breakdowns due to incorrect care?因为不正确的照顾而产生的故障频率有多高?,Types of Breakdowns 故障的型式,Function Loss(sporadic) Function Reduction (chronic) 丧失功能(偶发性) 功能降低(习惯性) Sudden Failures突然失效 Hidden隐藏的 Random无规则的 Expected/ignored预料中的/被忽视 Visible看得见 Minor impact影响较小,The Six Big Equipment Losses 设备的六大损失,Set-up and adjustments架模和调整 Set-up losses are the losses of time due to the physical changing of tooling, fixtures or dies. 架模损失是因为实际更换刀具、型规或模子而产生的时间损失 Adjustment losses are the additional time it takes, usually after a set-up, to “adjust” the equipment to ensure that we have an acceptable part. 调整损失通常是在架模之后,为了确保产出良品而额外耗用的调整设备时间,The Six Big Equipment Losses 设备的六大损失,Idling and minor stoppages空转和不严重的中断 Are the losses when we have small problems e.g. a part gets stuck in the machine, or other minor problems that dont require a mechanic. 这类损失是起因于小问题，如：零件卡在机器上或是其它不需要修理人员的次要问题,The Six Big Equipment Losses 设备的六大损失,Speed losses无法全速运转 Are the result of not being able to run at design or application speed. 因下列问题造成无法依照设计或规定的速度运转: Old worn machine老旧损耗的机器 Loose drive belts皮带松动 What is the design/application speed?设计/规定的速度是多少? Never tested at the design/application speed从未测试能否以设计/规定运转,Start-up/yield losses (reduced yield between machine start-up and stable production) 起动/生产损失(机器起动到稳定生产之间的产量缩减) These types of losses can result for the same reason as adjustment and set-up losses. 这一类的损失可能与调整和架模损失具有相同的起因 The time it takes to correct defects caused by tooling, warm-up, or other start-up issues. 为了改正由于加工、暖机或其它启动原因造成的不良品所耗用的时间,The Six Big Equipment Losses 设备的六大损失,Quality defects and rework报废和重工 In general this is the result of producing defective parts due to an adjustment, fixture, measurement system error. 通常是由于调整、型规、量测系统错误而产出不良品,The Six Big Equipment Losses 设备的六大损失,Overall Equipment Effectiveness 总体设备有效率,Skip Section,Overall Equipment Effectiveness 总体设备有效率,A measure of value-added to production through equipment.一种对设备加值生产的评量方式 Improving the equipments total availability and productivity.增进设备的总体可用力和生产力 Reducing defects while stabilizing and improving quality.当生产稳定时可减少不良品并改善品质,How Losses Affect Production 损耗如何影响生产,Hours Available per Day = 8.5每日可用时间 Schedule Work Time = 8 Hrs排程工作时间,Schedule Time = Scheduled Work Hours * 60 Minutes 排程时间 = 排程工作时间 * 60 分钟,Not scheduled 30 min. 未排程时间 30分钟,Schedule Time = 8 hours * 60 minutes = 480 minutes 排程时间 = 8 小时 * 60 分钟 = 480分钟,Availability 可用率,Running Time = Schedule time - Downtime Losses 运转时间 = 排程时间 - 停工损失,Availability =,Running Time = 480 - 85 = 395 运转时间 = 480 - 85 = 395,Availability =,Not scheduled 30 min. 未排程时间 30分钟,Schedule Time Time the Machine is in a Running Mode 排程时间 机器在运转状态的时间,Down time Losses 85 min 停工时间 损失85分钟,Running Time Schedule Time,运转时间排程时间,可用率 =,395480,= 82%,可用率 =,395480,= 82%,Performance 效能,Performance 效能 =,实际产量目标产量,Actual Output = Actual Number of Parts Produced 实际产量 = 实际生产数量,Actual Output = 1,277,Target Output = Ideal Cycle Time * Run Time 目标产量 = 理想周期时间 * 运转时间,Target Output = 4 parts/min * 395 = 1,580,Performance Loss 效能损失 = 1,580 1,277 = 303,= 81%,Performance 效能 =,1,2771,580,Quality Rate 品质良率,Good Output = actual output quality/defects losses 良品产量 = 实际产量 品质损失,Quality rate品质良率=,良品产量实际产量,Good Output = 1,277 20 = 1,257,= 98%,Not scheduled 30 min. 未排程时间 30分钟,Actual Output 实际产量,Down time Losses 85 min 停工损失 85分钟,Performance Loss 303 效能损失 303件,Q,Quality rate品质良率=,1,2771,257,Overall Equipment Effectiveness整体设备有效率,OEE = Overall Equipment Effectiveness,OEE = Availability Rate x Performance Rate x Quality Rate 可用率 效能比率 品质良率,OEE = 82% x 81% x 98% = 65%,Overall Equipment Effectiveness整体设备有效率,Appendix A Sample Forms 附件A 表格范例,Progress Measurement Form进度量测表,The following page has this form that can be printed and laminated to be posted on the machine.下一页也 有这张表格可以复印、分层以粘贴在机器上。,Completed Step Forms,The following page has this forms that can be printed and laminated to be posted on the machine. Use velcro to attach these to the Progress M