关键工厂指标

KEXIN Group SpecificationInd: A Transmitter : ENG TERMKey Industrial IndicatorsToolbox TABLE OF CONTENTS（目录）Purpose（目的）43Organization CHART（组织图）53Scraps - SC SCR（报废-报废成本-报废成本率）63Rejects RR（拒绝率）3Right First Time RFT（首次通过率）3Line Productivity - K1 - K2（ 生产线生产率 K1, K2 ）3Line Productivity - IP1 - IP2 - TP1 - TP2（生产线生产率 IP1 - IP2 - TP1 - TP2）3Equipment Availability - OEE - GEE EEE（设备利用率 - OEE - GEE EEE）3Equipment Reliability - MTBF - MTTR - MDT MTTF（设备可靠性- MTBF - MTTR - MDT MTTF）3Changeover Time CO TIME（换型时间 COT ）3Suppliers NC SQI（供应商不符合指标 SQI）3Safety - GC AWK（安全指标- GC AWK）3On Time Delivery OTD（准时交货率 OTD）3On Time In Full OTIF(整单准时交付 OTIF)3Customer Return CRR（客户退货率 CRR）3Absenteeism Rate ABS（缺勤率 ABS）3Ergonomics（人机工程学）3Environment（环境）3Improvement Ideas Problem Solving（改善提案问题解决）1003PURPOSE （目的） In order to:（为了） Support the deployment of the Kexin System （支持科信系统的应用） Have a common KeXin vocabulary （支持基于科信的通用词汇表） Simplify BU to BA reporting （简化从BU给BA的定期报告） Identify best practices （确定优秀的实践经验或方法）We propose a set of indicators respecting following criteria:我们提议一套遵循以下标准的工厂生产指标： Complete = coverage of the global production process (supplier to client)完整 = 覆盖整个生产工艺流程（从供应商到客户） Consistent = common definitions 一致性 = 一致的定义 Generated where the added value is created应用于增值的地方 Might be globalize可能具有全球性或集团化之处Some local specific indicators can complete this set with 2 restrictions:一些本地的具体的指标也可以完成这套词汇表，但有两点限制: Not substituting one or more of the key industrial indicators不可替代其中的一个或多个工业指标 Named differently (not only translation into local language)不同的命名方式(而不仅仅是翻译成本地语言)Its not mandatory to use all of them.并不一定要强制使用所有工厂生产指标In order to harmonize KeXin vocabulary, all the used indicators must respect the defined:为了协调好科信的词汇表，所有工业指标需如此定义: Naming (can be used in local language) 命名(要能够用于本地语言) Abbreviation缩写 Calculation formula计算公式3/51ORGANIZATION CHART（组织图表）Ergonomics 人机工程学Equipment Reliability(设备可靠性) MTBF，MTTR，MDT，MTTFRejects(不合格)RR 拒绝率仓库消费者 Quality 品质 Productivity 生产率 Customer 客户 People 人员全球指标全球本地指标Local IndicatorGlobal IndicatorScraps(报废)SC，SCR 报废率Line Productivity(生产线生产力)K1,K2Right First Time(首次通过率)RFTLine Productivity(生产线生产率)IP1，IP2，TP1，TP2Equipment Availability(设备综合效能) OEE，GEE，EEEChangeover Time（换型时间） CO TimeAutonomous Production Team自主管理的生产队伍Autonomous Production Unit自主性的生产单位Improvement Ideas/Problem solving(改善办法建议/问题解决) Suppliers NC（供应商不符合）SQI On Time Delivery（准时交货）OTDAbsenteeism ABS 缺勤率Environment 环 境Satety GC AWK 安全供应商 ScrapsSC, SCR RejectsRR Ergonomics AbsenteeismABS SafetyGC, AWK Environment Improvement Ideas / Problem solving Changeover TimeCO Time Right First TimeRFT Line ProductivityK1, K2 Line ProductivityIP1, IP2, TP1, TP2 Equipment Availability OEE, GEE, EEE Equipment ReliabilityMTBF, MTTR, MDT, MTTFBU / PLANT Delivery （交货）OTD, OTIFWAREHOUSECUSTOMERS Customer Returns （客户反馈）CRRSUPPLIERS6/49SCRAPS - SC - SCR Quality (品质) 报废-SC-SCR Productivityn Global indicator Customer 全球指标 Peoplen Local Indicator 本地指标Purpose & Description （目的和描述） Purpose（目的）The aim of this indicator is to measure the costs of lost materials or components. 这个指标的目的是测量损失物料或零件的成本。 Description（描述）There are 2 types of scrap indicators: 有两种报废指标- Scrap Costs （报废成本金额）- Scrap Cost Rate （报废成本率）OUT（输出）IN（输入）PROCESS（工序）PROCESSNOK（不合格不合格Rejects拒收Reworks返工 Scraps报废SC, SCR Unit（单位）- Unit for SC indicator: or local currency 报废成本金额指标单位：欧元或当地货币- Unit for SCR indicator:ppm 报废成本率指标单位：PPM Application field（应用范围）- Scrap Costs might be used as local and global indicator报废金额适用于本地和全球指标- Scrap Cost Rate might be used as local indicator报废率适用于本地指标How to calculate? （如何计算） Formula for Scrap Costs ( or local currency)报废金额计算公式欧元或本地货币）报废成本金额=所有报废物品的价值总和 Formula for Scrap Cost Rate (ppm)（报废成本率计算公式）所有报废物品的价值总和报废率=生产数量一个成品的所有零件的价值总和 Explanation of the formula（公式说明）For both formulas, the value to be considered is the value of the latest declaration in SAP or the latest cost taken into account.两种公式中的价值是指SAP中最近公布的价值或者采用最近的价值。Produced quantity is the total of good parts. 生产数量是合格品的总和。 Example of calculation （计算举例）Data（数据）- Good delivered quantity = 1000 products 合格交货数量=1000个产品- Product composed of 3 parts (A + B + C) 一个产品由3个部件组成（A+B+C）- Part（部件） A = 1 Scrapped （报废数）= 10- Part （部件）B = 0.1 Scrapped（报废数） = 2- Part（部件） C = 0.01 Scrapped （报废数）= 25- With S Value of scrapped parts（报废部件的价值总和） = 10.45 - And S Value of parts for one finished product（一个完成品的所有部件的价值总和） = 1.11 Scrap CostsScrap Cost Rate 报废金额 报废率（欧元）Application（应用） Scrap Costs ()（报废成本金额）- Easily understandable for direct workers（容易被直接工人理解）- Directly influenced by produced quantities（受生产数量直接影响） Scrap Cost Rate (ppm)（报废成本率）- Reporting to management (process tracking)（报告给管理层（过程跟踪）- Not sensitive to produced quantities（对生产数量不敏感） Example of larger application:（扩大应用举例）- More than production, the considered process can be the global process of the site: production, internal logistics and supply chain, R&D, Customer returnsso that every department is involved in the objective of scraps decreasing. The denominator of the formula becomes the turnover.包括生产，考虑应用的工艺流程可以为工厂广泛意义上的流程：生产，内部物流及供应链，研发，客户退货等，以至每个部门都拥有减少报废的目标。这个公式的分母变成了营业额广泛意义上的每月用标准费用计算的保费成本（所有内部过程及外部DAQ）每月生产的业务总量（金额）Worlds Best Class（世界级水平） Scrap Costs（报废金额）- Optimum:close to 0 or local currency最佳：接近0欧元及本地货币 Scrap Cost Rate（报废率）- Optimum:close to 0 ppm最佳：接近0PPMREJECTS - RR Quality 拒绝 拒绝率 Productivity（生产力）n Global indicator Customer Peoplen Local Indicator 本地指标Purpose & Description （目的及描述） Purpose （目的）The aim of this indicator is to highlight the defaults during a process. 这个指标的目的是突现在某一工序过程期间的缺陷 Description （描述）PROCESS 过程OUT 输出IN 输入NOK 不合格 Reject Rate RR拒绝率Reworks返工Scraps报废 Unit （单位）- Unit for RR indicator: ppmRR拒绝率指标的单位：PPM Application field （应用范围）- Reject Rate might be used as local indicator此指标可作为本地指标How to calculate? （怎样计算） Formula for Reject Rate (ppm) 拒绝率的公式（PPM）拒绝货品的数量拒绝率 =率 =加工总数量 Explanation of the formula （公式说明）Processed quantity = quantity of parts gone into the process (OUT + NOK) 加工数量=投入加工的部件数量（产出+不合格的） Example of calculation （举例）Data(数据)- Processed parts = 3300 加工总部件数=3300- Rejected parts = 60 拒绝总部件数=60Rejected Rate（拒绝率）Application （应用）- Easily understandable for direct workers & line supports- 容易为直接工人及生产线辅助人员理解- Reporting to management (process tracking)报告给管理层（过程跟踪）Worlds Best Class （世界级水平）- Optimum:close to 0 ppm具体： 接近0PPMRIGHT FIRST TIME - RFT Quality 首次通过率 - RFT Productivity （生产力） Customer Peoplen Local Indicator 本地指标Purpose & Description （目的及描述） Purpose （目的）This indicator highlights the hidden loops. 这个指标显现隐藏的返工环节 Description （描述）输出Process 1过程1IN 输入OUT出Process 3过程3Process 2过程2Hidden loops 隐藏的返工环节 Unit （单位）- Unit for RFT indicator: %RFT的单位为：% Application field （应用领域）- Right First Time might be used as a local indicator linked to inspection or test during normal process.RFT指标作为本地指标，且与正常过程期间的检查或测试相联系How to calculate? （如何计算） Formula for Right First Time (%) 公式（%）最后一个工位的合格产品的数量首次通过率=每个工位生产的产品数量总和/工位数量 Example of calculation （计算举例）Data（数据）- Quantity of part “in” = 100 投入=100- Quantity of part “out” = 98 产出=98- Quantity of part processed on the 1st workstation: 103 第一个工位加工的部件数量：103- Quantity of part processed on the 2nd workstation: 117 第二个工位加工的部件数量：117- Quantity of part processed on the 3rd workstation: 109 第三个工位加工部件数量：109Right First Time（首次通过率）Application （应用）- Easily understandable for direct workers & line supports- 容易为直接工人及生产线辅助人员理解- Reporting to management (process tracking)报告给管理层（过程跟踪）Worlds Best Class （世界级水平）- Optimum:close to 100 %最佳： 接近100%LINE PRODUCTIVITY - K1 - K2 Quality 生产线生产力-K1-K2 Productivity（生产力） Customer Peoplen Local Indicator 本地指标Purpose & Description （目的与描述） Purpose （目的）K1: Productive part compared to allocated timeK1: 实际有效生产时间与生产理论标准时间之比.The aim of this indicator is to visualize the time spent on productive operations by direct labour* in comparison with allocated time. 该指数的作用是显现作业员实际用于生产操作的时间与生产理论标准时间之比。K2: Unproductive part compared to allocated timeK2: 非有效生产时间与理论标准时间之比.The aim of this indicator is to visualize the time spent on unproductive operations by direct labour* in comparison with allocated time. 该指数作用是是显现作业员用于非生产操作的时间与生产理论标准时间之比*: definition in “Explanation of the formula” / “Line Productivity IP1-IP2-TP1-TP2” 定义：“公式解释”/“生产线生产率IP1-IP2-TP1-TP2” Description （描述） Recorded Total Time for Direct Labour直接生产员工出勤记录的总工时Productive ctivities 生产活动Unproductive Activities非生产性活动ABProductive Activity生产活动Abatement (ex: medical, pregnancy, over 50 yo,)减少或消除（体检，怀孕）Training培训Meeting会义Infirmary医疗Delegation特别任务Non Quality品质不良Tests测试Frequency Cleaning大事件特别的清洁Animation (management)管理事件Reference change生产线转型号Miscellaneous (Technical)其他（关于技术层面的）Non working paid hours非劳动但需付薪酬时间K1K2Theoretical Time = Quantity X Allocated Time 生产理论时间 = 数量X指派时间 Unit （单位）- None （无） Application field （应用范围）- K1 and K2 might be used as local indicators K1与K2可用作本地的生产指数- K1 + K2 = IP1. See next indicator description. K1+K2=IP1 参照下一指数的描述How to calculate? (如何计算) Formula for K1 (用于K1的公式)实际有效生产时间分配时间中的生产(增值)部分=数量 x 理论标准时间 Formula for K2非有效生产的损失时间分配时间中的生产(增值)部分=数量 理论标准时 Explanation of the formula (公式解释)F Quantity = quantity of good parts 数量 = 合格产品的数量F Recorded Productive Time and Unproductive Operations Loss Time are either recorded by operators themselves and/or by shift manager 生产操作时间与非生产损失时间是由作业员自身或生产线管理人员记录的F Board of productive and unproductive activities (see above in description) 记录生产与非生产性的活动内容(参照以上的描述) Example of Calculation (计算举例) Recorded Total Time for Direct Labour直接生产员工出勤记录的总工时Productive ctivities 生产活动Unproductive Activities非生产性活动ABProductive Activity生产活动Abatement (ex: medical, pregnancy, over 50 yo,)减少或消除（体检，怀孕）Training培训Meeting会义Infirmary医疗Delegation特别任务Non Quality品质不良Tests测试Frequency Cleaning大事件特别的清洁Animation (management)管理事件Reference change生产线转型号Miscellaneous (Technical)其他（关于技术层面的）Non working paid hours非劳动但需付薪酬时间Time in hour时间(小时)9203020161030262476215Total Productive Time 总的有效生产工时950 hTotal Unproductive Time总的非生产工时183 hNumber of products产品数量168 274Theoretical Time理论标准时间862 hF K1 = (Productive Operations Recorded Time) / (Quantity X Allocated Time) K1 = 实际有效生产时间 / (数量 X 理论标准时)K1 = 950 / 862 = 1.10F K2 = (Unproductive Operations Loss Time) / (Quantity X Allocated Time) K2 = 非生产操作损失时间 / (数量 X 理论标准时)K2 = 183 / 862 = 0.21Application (应用)- Easily understandable for direct workers 容易理解于直接生产工人- Be careful of the accuracy of the routings 留意工艺路线的精确性Worlds Best Class (世界级水平) K1:Optimum:close to 1 K2:Optimum:close to 0 最佳: 接近于1 最佳: 接近于0LINE PRODUCTIVITY - IP1 - IP2 - TP1 - TP2 Quality 生产线生产力-IP1-IP2-TP1-TP2 Productivity(生产力)n Global indicator Customer Peoplen Local Indicator 本地指标Purpose & Description (目的及描述) Purpose (目的)IP1: Index of Productivity 1 生产力指数1The aim of this indicator is to visualize the Total Time spent by direct labour* in comparison with allocated time. 该指数作用是比较生产员工出勤记录的总工时与总的理论标准操作时间IP2: Index of Productivity 2 生产力指数2The aim of this indicator is to visualize the Total Time spent by direct* and indirect labour* in comparison with allocated time. 该指数作用是比较生产员工和间接员工出勤记录的总工时与总的理论标准操作时间TP1: Time per Product 1 用于每个产品的时间1The aim of this indicator is to visualize the Total Time spent by direct labour* to produce one product. 该指数是表示直接生产员工用于完成一个产品的操作时间TP2: Time per Product 2 用于每个产品的时间2The aim of this indicator is to visualize the Total Time spent by direct* and indirect labour* to produce one product. 该指数是指直接员工和间接员工去完成一个产品所需的时间 Unit (单位)- Unit for IP1 and IP2:None IP1与IP2：无- Unit for TP1 and TP2:Minute/Product TP1与TP2 ：分钟/产品 Application field （应用范围）- IP1 and IP2 might be used as local indicatorsIP1与IP2是用于本地的指数- TP1 and TP2 might be used as local indicatorsTP1与TP2是用于本地的指数*: definition in “Explanation of the formula”How to calculate? (如何计算) Formula for IP1 = K1 + K2出勤总工时(直接员工）生产力指数1= K1+ K2数量 理论标准时间 Formula for IP2出勤总工时(直接与间接员工) 生产力指数2=数量 x 理论标准时间 Formula for TP1 (min/product)出勤总工时(直接员工) 每个产品完成时间1=数量 Formula for TP2 (min/product)出勤总工时(直接与间接员工) 每个产品完成时间2=数量 Explanation of the formula（公式解释）F Direct Labour = “Operators who add value to the KeXin manufactured products. Apart from rare exceptions (people assembling units in market areas), manufacturing direct people should only be registered in business areas.” (Financial Manual 4.0). There are operators, line leaders who assemble products. 直接员工 = 是指那些可以使科信产品得以增值的作业员,部分人(在市场部做成品装嵌的人员)除外,仅限于在制造区域登记的作业人员(财务册4.0).产品装配线的作业员,线长F Indirect Labour = “Headcount who does not directly add value in the production process” (Financial Manual 4.0). There are storekeepers, quality technician, and production responsible (All people in the section of production except Direct Labour) 非直接员工 = 不直接使产品增值的职员,(财务手册4.0),比如仓管员,品质人员,技术人员,或生产管理人员.(除直接员工外所有工作于生产区域的人员)F Quantity = quantity of good products 数量 = 合格的产品数量F All the times used in precedent formula are recorded by the direct labour themselves and/or by the staff management 以上公式的时间是由员工自身或管理人员记录的. Recorded Total Time for Direct Labour直接生产员工出勤记录的总工时 Recorded Total Time for Indirect Labour记录非直接生产员工的总工时Productive ctivities 生产活动Unproductive Activities非生产性活动ABCProductive Activity生产活动Abatement (ex: medical, pregnancy, over 50 yo,)减少或消除（体检，怀孕）Training培训Meeting会义Infirmary医疗Delegation特别任务Non Quality品质不良Tests测试Frequency Cleaning大事件特别的清洁Animation (management)管理事件Reference change生产线转型号Miscellaneous (Technical)其他（关于技术层面的）Non working paid hours非劳动但需付薪酬时间 Example of Calculation Recorded Total Time for Direct Labour直接生产员工出勤记录的总工时 Recorded Total Time for In-Direct Labour记录非直接生产员工的总工时Productive ctivities 生产活动Unproductive Activities非生产性活动Unproductive Activities非生产性的活动ABCProductive Activity生产活动Abatement (ex: medical, pregnancy, over 50 yo,)减少或消除（体检，怀孕）Training培训Meeting会义Infirmary医疗Delegation特别任务Non Quality品质不良Tests测试Frequency Cleaning大事件特别的清洁Animation (management)管理事件Reference change生产线转型号Miscellaneous (Technical)其他（关于技术层面的）Non working paid hours非劳动但需付薪酬时间Time in hours时间:小时9203020161030262476215105Total Productive Time总生产工时950 hTotal Unproductive Time总非生产工时183 h Recorded Total Time (Direct Labour)记录的生产工时1133 h or 67980 minRecorded Total Time (Indirect Labour)己记录的非生产工时105 h or 6300 minNumber of products产品数量168 274Theoretical Time理论时间862 h or 51720 minF IP1 = (Recorded Total Time for Direct Labour) / (Quantity X Allocated Time) IP1=总工时(直接员工)/(数量 X 理论时间)IP1 = 67980 / 51720 =1.31 (=K1+K2)F IP2 = (Recorded Total Time for Direct & Indirect Labour) / (Quantity X Allocated Time)IP2=总工时(直接和非直接员工)/ （数量X 理论时间）IP2 = (67980 + 6300) / 51720 =1.43F TP1 = (Recorded Total Time for Direct Labour) / Quantity TP1=总工时(直接员工)/数量TP1 = 67980 / 168274 =0.40 min/productF TP2 = (Recorded Total Time for Direct & Indirect Labour) / QuantityTIP2=总工时(直拉和非直接员工)/数量TP2 = (67980 + 6300) / 168274 =0.44 min/productApplication (应用) TP1, TP2- Easily understandable for direct workers易于理解直接员工Worlds Best Class (世界级水平)EQUIPMENT AVAILABILITY - OEE - GEE - EEE Quality 设备利用率-OEE-GEE-EEE Productivity（生产力）n Global indicator Customer Peoplen Local Indicator 本地指标Purpose & Description（目的和描述） Purpose（目的）OEE: Overall Equipment Eff