关键绩效(KPI)指标--培训.

1、 Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Key Performance Indicators Training 关键绩效指标关键绩效指标培训培训 Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. The Need to Measure 衡量的必要性 2 To unde

2、rstand the current situation 了解现状 To identify the focus areas for improvement 确定需要改进的关键区域 To identify the improvement target 确定改进目标 To identify the impact of improvement activity 确认改善行动的影响 To ensure sustainability and drive further continuous improvement activities 确保持续性并深入推动持续改进行动 Why do we need to

3、 measure? 为什么要进行衡量 Visual Factory Waste elimination & Standard Work Safety Productive Maintenance Quality Demand Flow Continuous Improvement Working in Teams Leadership People Development & Involvement Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Key Performance Indicators (

4、KPIs) 关键业绩指标 3Key 图解: Strong Correlation. 关系密切 Some Correlation 少许联系 EASURE 衡量标准 QUALITY 质量 COST 琛本 DELIVERY 交货 SAFETY 安全 BBRIVIATION 缩写 Safety 安全 Total Case Incident Rate 总计事故发生率总计事故发生率 TCIR Productivity 生产率 Labour Productivity 人工效率人工效率 LP Production Quality 生产质量 Not Right First Time 一交不合格率一交不合格率 N

5、RFT Product Quality 产品质量 Service Call Rate 电话投诉率（社会返修率）电话投诉率（社会返修率） SCR Production Delivery 交货 Delivery Schedule Achievement 按时交货率按时交货率 DSA Production Inventories 生产库存 Stock Turns WIP & Supplies 在制品在制品&物料库存周转率物料库存周转率 STWS Warehouse Inventories 仓库存货 Stock Turns Finished Goods 成品库存周转率成品库存周转率 STFG Conv

6、ersion Costs 加工成本 Conversion Cost per Product 单台加工成本单台加工成本 CCPP Equipment Efficiency 设备效率 Overall Equipment Efficiency 设备综合利用率设备综合利用率 OEE Production Efficiency 生产效率 Disruption Free Performance 无中断运行无中断运行 DFP Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Total Cases Incident R

7、ate总计事故发生率 4 A measure of Safety considering workplace injuries in relation to hours worked. 与工作时间相关的工伤方面的安全测定标准 TCIR = Annual total no. of hours worked 200 000 (hrs) annual no. of recordable accidents incurred 200 000（小时）小时） 年度记录在案的事故发生数量年度记录在案的事故发生数量 年度总工时年度总工时 Unit: rec.acc./100 workers/year 单位:

8、（事故记录数量/100个工人/每年） 200 000 = 100 workers 50 weeks 40 hours per week 200 000 = 100个工人 50周每周40小时 Recordable accidents 记录在案的事故 Annual number of recordable accidents incurred 年度记录在案的事故发生数量 Annual total number of hours worked 年度总工时 Data Required: 所需数据： Electrolux 2006 All Rights Reserved. Revision 1 issu

9、ed on 15/05/2006. Labour Productivity 人工效率 5 A measure of the ratio between good units made and the direct and indirect operator hours used to make them. 合格品与对应的直接及间接人工工时之间的比值测定标准 LP = Number of direct and indirect paid operator hours 直接及间接人工工时直接及间接人工工时 Total quantity of FG units produced 成品生产总量成品生产

10、总量 Unit: prod/hour 单位：（产品台数/小时） FG = Finished Good unit. FG =成品台数 Data Required 所需数据： Total quantity of FG produced 成品生产总量 Number of direct and indirect paid operator hours 直接和间接人工工时 Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Not Right First Time 一交不合格率 6 A measure of the

11、quality of a product / process ability to match the specification 产品质量 / 工艺能力与规范的匹配性的测定标准 Total quantity of units produced 生产总台数生产总台数 Number of defective units 缺陷台数缺陷台数 NRFT = 1 million 一百万一百万 Unit: parts per million, ppm 单位： （百万分率，PPM） Data Required 所需数据： No of units produced 生产台数 No of units scrap

12、ped 报废台数 No of units reworked 返修台数 Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. SCR 电话投诉率（社会返修率） Service Call Rate 7 SCR = Number of FG units repaired by After Sales Service 售后服务提供的成品维修数量售后服务提供的成品维修数量 Total quantity of FG units sold 成品销售总量成品销售总量 Product Quality is measured t

13、hrough Service Call Rate as already in use 通过现有的SCR来衡量产品质量 Unit: % 单位： （%） Data Required: 所需数据 No of finished good units sold 成品销售总量 No of finished good units repaired by After Sales Service售后服务提供的成品维修数量 FG = Finished Good unit. FG = 成品台数 Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/

14、05/2006. Delivery Schedule Achievement 按时交货率 8 A measure of how well a supplier matches the delivery requirements according to a frozen plan. 厂家根据固定计划完成交货要求的测定标准 Units: Percent % 单位：(%) Data Required: 所需数据： Number of planned units (Number of planned units frozen for 5 working days) 计划台数 （5个工作日之内的固定计

15、划台数） Number of incorrect units (A unit is incorrect when it is not in time, not in correct quantity, not in correct sequence or not conforming to frozen plan, different PNC or production line.) 生产误差台数 （未及时、未按数量要求、未按正确的工序或不符合固定计划、 PNC码不相符或生产线不一致的台数） 100% No. of planned units 计划生产台数计划生产台数 No. of plann

16、ed units No. of incorrect produced units 计划台数计划台数 生产误差台数生产误差台数 DSA = Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Stock Turns Wip & Supplies 在制品&物料存货周转率 9 A measure of how frequently the WIP & Supplies Inventory is turned over in relation to annual Cost of Materials. 与年度材料成本

17、相关的在制品&物料存货周转频率的测定标准 Data Required: 所需数据： 12 month rolling period Cost of Materials: 12个月滚动周期的材料成本 12 month rolling average of Wip & Supplies Inventory value: 在制品&物料存货价值 的12个月滚动平均数 STWS = 12 month rolling ave of Wip&Supplies Inventory value 在制品在制品&物料存货物料存货12个月的滚动平均值个月的滚动平均值 12 month rolling period C

18、ost of Materials 12个月滚动周期的材料成本个月滚动周期的材料成本 Unit: frequency 单位： （频率） Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Stock Turns Finished Goods 成品库存周转率 10 A measure of how frequently the FG stock is turned over in relation to the annual FG sold (STK2). 与年度成品销售（STK2）相关的成本库存周转频率的测定

19、标准 Data Required: 所需数据： 12 month rolling period Cost of FG sold: 12个月滚动周期内销售的成品成本： 12 month rolling average of Finished Goods Inventory value: 成品库存的12个月滚动平均值： STFG = 12 month rolling ave of FG Inventory value 成品库存的成品库存的12个月滚动平均值个月滚动平均值 12 month rolling period Cost of FG sold 12个月滚动周期内销售的成品成本个月滚动周期内销

20、售的成品成本 Unit: frequency 单位： （频率） Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Conversion Cost Per Product 单台加工成本 11 A financial measure which relates the number of products produced to the cost of producing them. 将产品生产数量与其生产成本联系起来的财务测定标准 CCPP = Total quantity of FG units prod

21、uced 生产的成品总量生产的成品总量 STK1 including variance DM including variances 包括差异的包括差异的STK1 包括差异的包括差异的DM Unit: or$/ product 单位： （欧元或美元/台） FG = Finished Good unit. FG = 成品台数 Data Required: 所需数据： Total quantity of FG units produced 生产的成品总量 STK1 including variances 包括差异的STK1 Represents the sum of DM, DL, DL-b, O

22、DC, FO-v, including variances 表示包括差异的直接原材料,直接人工,直接人工福利, ODC, 变动制造费用总量 Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Overall Equipment Efficiency 设备综合利用率 12 A measure of how efficiently a process is producing parts within the time it is planned to run 对工序流程在计划运转时间内生产零件的效率的测定标准

23、 OEE = Availability% Performance% Quality% OEE = 利用率利用率% 性能性能% 合格率合格率% Availability compares how much time the process was actually producing in relation to the time it was planned to run 利用率是实际生产流程时间与计划运行时间的对比 Performance compares the theoretical time to process the produced quantity to the actual

24、time to produce them 性能是生产一定数量产品的理论时间与实际生产时间的对比 Quality compares the number of parts that are right first tme from the process with total quantity of parts processed 合格率是加工一次合格部件数量与部件加工总量的对比 Data Required: 所需数据： Right first time level of process (100% - NRFT%) 加工一次合格率水平（100% - 一交不 合格率） Total availab

25、le time 总计利用时间 Downtime losses planned and unplanned 停机时间损失计划的和非计划的 Actual operating time taken to produce parts in period 周期内生产部件的实际操作时间 Number of parts produced in that period 该周期内生产的部件数量 Ideal cycle time for the part through the process 该部件加工的理想周期 Electrolux 2006 All Rights Reserved. Revision 1 i

26、ssued on 15/05/2006. Overall Equipment Efficiency 设备综合利用率 13 _ _ _ Total available time 总计利用时间总计利用时间 Planned downtime 计划停机时间计划停机时间 Unplanned downtime 非计划停机时间非计划停机时间 Total available time 总计利用时间总计利用时间 Planned downtime 计划停机时间计划停机时间 Availability = 利用率利用率 x 100% Performance = 性能性能 Ideal cycle time x Proc

27、essed quantity 理想周期理想周期 x 加工数量加工数量 Actual operating time 实际操作时间实际操作时间 x 100% Quality = 合格率合格率 Processed quantity Defect Quantity 加工数量加工数量 缺陷数量缺陷数量 Processed quantity 加工数量加工数量 x 100% Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Overall Equipment Efficiency 设备综合利用率 14 1000 625

28、 250 125 I plan to run a machine for 10hrs, with a cycle time of 0.6 min/part : Potential Output = 1000 parts. 计划让机器运转计划让机器运转10小时，周替为每个零件小时，周替为每个零件0.6分钟：可能的产量分钟：可能的产量 =1000个个 But if I lose 3 hrs to breakdown,2 hrs to a changeover. 但如果故障停机但如果故障停机3个小时，又花了个小时，又花了2个小时进行设备转换。个小时进行设备转换。 Availability = ?%

29、Max. Possible Output = ? parts 利用率利用率=?% 最大产量可能最大产量可能=?个个 But if we have to run slowly due to machine condition and because I am a new operator, I only make 250 parts in the 5 hours available. 但是如果由于机器情况不得不让其运转速度放慢，再加上我是个新但是如果由于机器情况不得不让其运转速度放慢，再加上我是个新 手，我只能在手，我只能在5个小时内做个小时内做250个零件。个零件。 Performance =

30、 ?% Actual Output = 250 parts 效能效能=?% 实际产出实际产出=250个个 OEE concept example: 设备综合利用率案例：设备综合利用率案例： Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. Overall Equipment Efficiency 设备综合效率 15 And if half of the parts that we do make require rework to make them in tolerance. 并且如果我们生产的零件有一

31、半需要按要求返工，以使其在规定并且如果我们生产的零件有一半需要按要求返工，以使其在规定 公差范围之内公差范围之内 Quality = ?% Good Parts Produced = ? 合格率合格率 =?% 生产的合格品生产的合格品=? OEE（设备综合利用率）设备综合利用率） = ?% x ?% x ?% ?=?% 1000 625 250 125 Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. 16 OEE Worked Example OEE实例 A machine operates on on

32、e shift of eight hours with 20 minutes for breaks 假设一台机器8小时单班，期间会有20分钟计划停机时间. Yesterday the machine stopped for 20 min for tooling, 20min for breakdown and 20 min for adjusting昨天该机器修模停了20分钟，故障 20分钟，调试20分钟。 All planned maintenance is carried out outside the normal shift time (8 hours)按计划机器维护安排在正常生产时间

33、以后（8小时以后） Normal planned output is 460 units. Yesterday the machine made 350 parts of which 20 were scrapped and 30 reworked. Machine cycle time is 1 minute计划产量为460台。但昨天只生产了350台，其中20台报废，30 台返工，设备循环周期为1分钟。 What is the O.E.E. of the machine问该设备的OEE是多少？ Electrolux 2006 All Rights Reserved. Revision 1 issued on 15/05/2006. 17 利用率利用率 = 总可用时间总可用时间 计划停机时计划停机时 非计划停机时节非计划停机时节 x 100% 总可用时