精益生产——设备利用率.ppt

TheSixBigEquipmentLosses设备的六大损失,TheSixBigEquipmentLosses设备的六大损失,Breakdowns故障停工Set-upandadjustments架模和调整Idlingandminorstoppages闲置(空转)和不严重的中断Speedlosses无法全速运转Start-up/yieldlosses(reducedyieldbetweenmachinestart-upandstableproduction)起动/生产损失(机器起动到稳定生产之间的产量缩减)Qualitydefectsandrework报废和重工,TheSixBigEquipmentLosses设备的六大损失,Breakdowns故障停工Thetimethatislostforproductionduetoequipmentfailures.由于机器故障而损失了生产时间Howmanyhoursamonthislostduetobreakdowns?每个月因机器故障而损失了多少小时?Isitnormaltofightthebreakdownfires?紧急处理机器故障是属于正常的情况吗?Howoftendowehavebreakdownsduetoincorrectcare?因为不正确的照顾而产生的故障频率有多高?,TypesofBreakdowns故障的型式,FunctionLoss(sporadic)FunctionReduction(chronic)丧失功能(偶发性)功能降低(习惯性)SuddenFailures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Minorimpact影响较小,TheSixBigEquipmentLosses设备的六大损失,Set-upandadjustments架模和调整Set-uplossesarethelossesoftimeduetothephysicalchangingoftooling,fixturesordies.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Adjustmentlossesaretheadditionaltimeittakes,usuallyafteraset-up,to“adjust”theequipmenttoensurethatwehaveanacceptablepart.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,TheSixBigEquipmentLosses设备的六大损失,Idlingandminorstoppages空转和不严重的中断Arethelosseswhenwehavesmallproblemse.g.apartgetsstuckinthemachine,orotherminorproblemsthatdontrequireamechanic.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,TheSixBigEquipmentLosses设备的六大损失,Speedlosses无法全速运转Aretheresultofnotbeingabletorunatdesignorapplicationspeed.因下列问题造成无法依照设计或规定的速度运转:Oldwornmachine老旧损耗的机器Loosedrivebelts皮带松动Whatisthedesign/applicationspeed?设计/规定的速度是多少?Nevertestedatthedesign/applicationspeed从未测试能否以设计/规定运转,Start-up/yieldlosses(reducedyieldbetweenmachinestart-upandstableproduction)起动/生产损失(机器起动到稳定生产之间的产量缩减)Thesetypesoflossescanresultforthesamereasonasadjustmentandset-uplosses.这一类的损失可能与调整和架模损失具有相同的起因Thetimeittakestocorrectdefectscausedbytooling,warm-up,orotherstart-upissues.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,TheSixBigEquipmentLosses设备的六大损失,Qualitydefectsandrework报废和重工Ingeneralthisistheresultofproducingdefectivepartsduetoanadjustment,fixture,measurementsystemerror.通常是由于调整、型规、量测系统错误而产出不良品,TheSixBigEquipmentLosses设备的六大损失,OverallEquipmentEffectiveness总体设备有效率,SkipSection,OverallEquipmentEffectiveness总体设备有效率,Ameasureofvalue-addedtoproductionthroughequipment.一种对设备加值生产的评量方式Improvingtheequipmentstotalavailabilityandproductivity.增进设备的总体可用力和生产力Reducingdefectswhilestabilizingandimprovingquality.当生产稳定时可减少不良品并改善品质,HowLossesAffectProduction损耗如何影响生产,HoursAvailableperDay=8.5每日可用时间ScheduleWorkTime=8Hrs排程工作时间,ScheduleTime=ScheduledWorkHours*60Minutes排程时间=排程工作时间*60分钟,Notscheduled30min.未排程时间30分钟,ScheduleTime=8hours*60minutes=480minutes排程时间=8小时*60分钟=480分钟,Availability可用率,RunningTime=Scheduletime-DowntimeLosses运转时间=排程时间-停工损失,Availability=,RunningTime=480-85=395运转时间=480-85=395,Availability=,Notscheduled30min.未排程时间30分钟,ScheduleTimeTimetheMachineisinaRunningMode排程时间机器在运转状态的时间,DowntimeLosses85min停工时间损失85分钟,RunningTimeScheduleTime,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,ActualOutput=ActualNumberofPartsProduced实际产量=实际生产数量,ActualOutput=1,277,TargetOutput=IdealCycleTime*RunTime目标产量=理想周期时间*运转时间,TargetOutput=4parts/min*395=1,580,PerformanceLoss效能损失=1,5801,277=303,=81%,Performance效能=,1,2771,580,QualityRate品质良率,GoodOutput=actualoutputquality/defectslosses良品产量=实际产量品质损失,Qualityrate品质良率=,良品产量实际产量,GoodOutput=1,27720=1,257,=98%,Notscheduled30min.未排程时间30分钟,ActualOutput实际产量,DowntimeLosses85min停工损失85分钟,PerformanceLoss303效能损失303件,Q,Qualityrate品质良率=,1,2771,257,OverallEquipmentEffectiveness整体设备有效率,OEE=OverallEquipmentEffectiveness,OEE=AvailabilityRatexPerformanceRatexQualityRate可用率效能比率品质良率,OEE=82%x81%x98%=65%,OverallEquipmentEffectiveness整体设备有效率,AppendixASampleForms附件A表格范例,ProgressMeasurementForm进度量测表,Thefollowingpagehasthisformthatcanbeprintedandlaminatedtobepostedonthemachine.下一页也有这张表格可以复印、分层以粘贴在机器上。,CompletedStepForms,Thefollowingpagehasthisformsthatcanbeprintedandlaminatedtobepostedonthemachine.UsevelcrotoattachthesetotheProgressMeasurement