【课件】设备全局效率OEE

LeanSixSigmaBoot-camp

MCK-KCI精益运营项目_设备全局效率OEE1

Tableofcontent

內容1Learningobjective&TOC

学习目的和内容WhatisOEE?

什么是OEELinkingOEEtoPerformance

链接OEE到绩效IntroductionofOEEprogram

介绍OEE程序Conclusion

结论3-14

16-2123-2426ExplainthepurposeofdeterminingOverallEquipmentEffectiveness(OEE)

解释OEE的目的UnderstandhowOEEhelpsdriveperformanceaspart

ofaleanproductionsystem

了解精益生产系统中OEE如何帮助绩效改善Attheendofthissessionyouwillbeableto

本节学习完你将会PageLearningobjective

学习目的2

2Agenda

OverallEquipmentEffectiveness(OEE)WhatisOEE?

什么是OEELinkingOEEtoPerformance

链接OEE到绩效IntroductionofOEEprogram

介绍OEE程序Conclusion

结论3

3WhatisOEE?

什么是OEEDefinition:Ashopfloortooltomeasurehowwellmanufacturing

equipmentisrunningwhencomparedtothetheoreticalgoal定义：用来跟理论产值比较以评估生产设备的运作效率的现场工具Theuseof

OEEiscriticaltosupportingtheleantooldeploymentOEE的运用对于支持精益工具开展具有重要意义CellDesignMaterialReplenishment&FlowSixSigmaQuickChangeOver(QCO)VoiceoftheCustomer(VOC)TotalProductiveMaintenance(TPM)ProductionPreparationProcess(3P)MistakeProofingStandardWorkVisualFactoryQualityControlProcessCharts(QCPC)5SValueStreamMapping4

3WhyisOEE?为什么是OEE？OEEtakesthemostcommonandimportantsourcesofproductivitylosses,andplacestheminto3categoriesOEE涉及的是生产最常见最重要的损失来源，并将它们划分为3类Availability–anylossthatstopsplannedproduction

时间利用率-导致计划生产停止的任何损失Performance–anylossthatcausesplannedproductiontooperateatlessthanmaximumpossiblespeed

设备性能率-导致计划生产以低于最大可能速度进行的损失

Quality–anylossarisingfromproducedpartsthatdonotmeetqualitystandards

品质合格率-导致产品不符合质量标准的损失OEEgivesustheoverallpictureofmachineperformance,notfocusingjustonefficiencyorutilizationOEE给我们呈现的是机器效能整体状况，而不是只专注于效率或利用率OEEismeasuredatamachinelevelOEE是用来测量机器的AmeasureofTruecapacityofprocess机器真实产能的衡量Prioritizedwaytoeliminatelossesofprocess消除流程损失的优先方式5

OEEbreakdown

OEE分类TotalShiftTime(24hrsx365days)返时间(24小时X365天)OEE

Losses6BigOEELossesAvailableProductionTime可利用时间EffectiveTime创造价值的时间Takingproductivitylossesintoaccount,effectiveproductiontime

(timethatgoodpartsareproduced)isonlyafractionofwhatisavailable将产能损失分成不同的项，有效的生产时间(生产出好产品的时间)

只是总可利用时间的一部分PlannedStops计划停机时间Availabilitylosses停机损失Performancelosses性能損失Qualitylosses质量损失Scrap废品Rework

返工MinorStops小停机ReducedSpeed降速Breakdowns

故障停机Changeovers換型6

ThesixbigOEElosses

六类主要OEE损失Loss损失Category种类Description描述EventExamples举例Breakdowns故障Availability时间利用率Machinestopduetoatechnicalproblemordamage由于技术或者损坏所导致的停机Duration>15minutes停机达15分钟以上Requiresrepairtofix需要修理以解決Changeovers换型Availability时间利用率Stopsinproductionduetomaterialortoolingchanges原材料或者工具的改变导致的生产中停机MinorStops小停机Performance设备性能率Machinestopduetoprocessproblem

工艺问题导致的停机Norepairofcomponentsrequired,afterprocessadjustmentsandcleanup

经过工艺调整或者情急，无需修理Machineisrunningagain<<15min

少于（或者等于15mins）可再开机ReducedSpeed降速Performance设备性能率Actuallinespeedsthatfallbelowratings低于目标速度的实际速度Scrap废品Quality品质合格率Defectivepartsproducedduringnormaloperations正常操作中所生生的不合格品Rework

返工Quality品质合格率Partsthatfailinspection,butcanbefixedtomeetspecifications产品未通过检验，但可经过修复满足标准1456Unplannedmaintenance非计划维修Equipmentfailures设备故障Shiftingthelinefrom

PartAtoPartB产品A换到产品BJammedcomponents

产品堵CleaningorChecking

清洁或者检查Equipmentwear

设备磨损Operatoradjustments

操作工调整In-processdamage

过程中的损坏Badmaterialinputs

不良原材料导入Incorrectassembly

错误的裝配In-processexpiration

过程中的吹落237

OEE–visualoverviewoflosses损失可视化概述SampleLineOEE,Hour(perweek)This“scheduledtime”measurementisoftencalledOEE2andisthemostpertinentforperformancemeasurementandmanagement“计划时间”测量通常称为OEE2，是绩效测量和管理有效的衡量方式

20OEE148%OEE267%“Thetimethemachineisscheduledtorunduringthemonth”本月内机器计划开机时间Thisleavesuswith120hrsuponwhichtobaseonperformancemeasurements基于设备性能率测量方法，这个时间是120小时8

OEE–visualoverviewoflosses损失可视化概述SampleLineOEE,Hour(perweek)

20OEE148%OEE267%“Theremainingtimeafterbreakdownandchangeoversandexternaloutagesareconsidered”除了故障，换型和外部中断所剩余的时间AvailabilityLoss时间利用率损失PerformanceLoss设备效率损失9

OEE–visualoverviewoflosses损失可视化概述SampleLineOEE,Hour(perweek)

20OEE148%OEE267%“Theremainingtimewhenlossesfromnotfollowingstandardspeedsandminorstopsareconsidered”除去未开到标准速度和小停机剩余的时间QualityLoss质量损失10

OEE–visualoverviewoflosses损失可视化概述SampleLineOEE,Hour(perweek)

20OEE148%OEE267%“Theremainingtimewhenlossesfromscrapareconsidered”除去生产废品时间后的剩余时间OEEcalculationOEE计算11

OEEAvailabletime可利用时间Nettime净利用时间Time-based时间为依据Part-based产品数量为依据OEEQuantityofpartsthatshouldtheoreticallybeproduced理论产品数Quantityofactualgood

partsproduced实际好产品数Therearetwo(2)methodsforcalculatingOEE1

计算OEE1有两种方法1Dependsupontimeand/orpartdataavailability12

CalculatingOEE–example

计算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计算OEE-例子OperatingtimeChange-overs80.0Break-downsAvailableproduc-tiontimeSched-uledMainte-nanceUnsched-uledProduc-

tionTotalplant

time172.0Effectiveproduc-tiontimeReworkScrapRunningtime216.0ReducedspeedMinor

stops36%OEEAvailabilitylossPerformancelossQualityloss14

PerformancesummaryreportfromOEEOEE绩效总结报告ScheduletimeAvailabletimeOperatingtimeNettimeOEE(%)XXXXXXXXXX“Wecanclearlyunderstandwherewe’reanddecidethedirectionforimprovementthroughOEEanalysis”通过分析OEE，我们可以清楚地知道我们的位置，同时确定改善的方向15

7Agenda

OverallEquipmentEffectiveness(OEE)WhatisOEE?

什么是OEELinkingOEEtoPerformance

链接OEE到绩效IntroductionofOEEprogram

介紹OEE程序Conclusion

结论16

BenefitsofOEE

OEE的好处ImprovingOEEcanhaveasignificantimpactonbusinessperformance改善OEE对绩效有显著的影响Reduce

cost降低成本Impact

影响度Performancemetric

绩效Sourceofimpact

影响源Improvequality质量提升Rejects(scrap,rework)

拒收(废品，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/快速的备货率On-timedeliverytocustomer(rightquantity,quality,andtime)及時送貨到客戶(數量，质量，时间)Reduceddowntimeandscrapcreatesstability,allowingadherencetotheschedule降低停机时间及不合格率，创造稳定及符合生产排产Inventory库存ReducedscrapraterequireslessWIP降低不良品可使白片减少Productivity产量Withlessdowntime,peoplehavemoretimeforValueAddedwork少的停机，人们有更多的时间从事增值工作Capex(capitalexpenditures)资本支出Latentcapacityreleased潜在的产能提升17

OEEimprovementtoollevers

OEE改善工具Availability时间利用率Quality质量合格率Improvementapproaches改善方法5SStandard

work标准化工作GOMeetingsGO会议QCO快速換型TPM全员参与性维护Breakdowns故障停机Changeover换型Minorstops小停机Reducedspeed降速Scrap废品Rework返工RelevanceLowHighLossCategory损失种类Performance设备性能率18

AddressingthesixbigOEElosses

分析六大OEE损失Breakdowns故障停机Movingpartsandvariousmachinesubsystemsfail(forexample,conveyorbeltbreaks)运动部件及各重机器子系统失效(例如：皮带断)Empowerworkerstoperformbasicmaintenancetasks授权给操作工能完成基本的维修工作Conductplannedmaintenance–bothpreventiveandpredictivemaintenance完成计划维修

–包含预防性和预知性保养Changeover换型Timerequiredtosetupmachineforadifferentpart需要时间去设定机器的不同部位Cleaningandadjustments清洁和调整Locatingtools,parts,people工具，备件和人员的定位Startup–defectiveproductsmadewhileworkerstestfor

stableoutput

启动–当现场人员测试稳定生产时产生的不良品EmployQCO(QuickChangeover)toshortenset-uptimes

使用快速换型以缩短设定时间Separateinternalandexternal

changeover

分出內部工作及外部工作Convertinternalchangeover

toexternal

将內部工作转换成外部工作Streamlineallaspectsofchangeover换型活动顺畅化MechanicalJidoka–designmachineswithmistakeproofingsystemsthatautomaticallycheckconditionsandsignalwhenproblemsoccur

机械式自动化

–设计防错法的机器系统，能自

动检查状况及指出故障点Losses

损失Solutions

解决方案19

AddressingthesixbigOEElosses

分析六大OEE损失MinorStops小停机Trackproductionperformance

(forexample,hour-by-hourcharts)

跟踪生产绩效(例如每小时的图示)Conductroot-causeproblemsolvingtodeterminewhethertheproblemisstaff,material,methodormachine

运用根本原因问题解決办法，以弄清问题是否是人，机，料，法ImplementQCPCeffectively

有效的推动QCPC(过程品质管制图)ReducedSpeed速度降低Eventsthatinterruptproductionflowwithoutmachinefailure;

forexample,机器未故障所导致的中断生产，例如Labeldispenserneedsminorfixorreloading

标签机需要小的修理或者裝

标签Workerisnotavailabletostartupmachineafter

lunch午餐后人员未到位开机Machinerunsslowerthandesignedtooperate(forexample,apresscapableofcycling10strokesaminuteissetat5strokes)

机器开的比设计速度慢(例如一个冲床每分钟可冲10次，目前是设定5次)Losses

损失Solutions

解决方案20

Scrap废品Mistakeproofingtoeliminatethesourceofdefects

防错法以消除缺陷来源HumanJidoka(linestop,identifyandcall)–giveworkerstheauthoritytostopthelinewheneveranabnormalityordefectisfound人力自动化(生产线停机，确认及请求支援）–授权现场员工当不合格品或是缺陷产品产

出时，有权停机Rework

返工Productsorservicesfailingtomeetestablishedproductionspecificationsorcustomerrequirements产品或是服务失效，无法符合既定的生产规范或是客戶需求Productsthatrequirenon-standardoperationstomeetcustomerspecifications(forexampleproductsdamagedin-processthatrequirerepair)

产品需要透过不是标准的操作程式以符合客戶規格(产品过程中损坏需要修理)AddressingthesixbigOEElosses

分析六大OEE损失Losses

损失Solutions解决方案21

0OEEasameasureofcapacity

OEE作为设备能力的测量Futurestate

TaktTime–68.5未來的节拍时间

–68.5Current-state

TaktTime–94.7当前的节拍时间–94.7Op60Op50Op40Op30Op20Op10WithoutOEEimprovement,aCAPEXinvestmentisrequiredtopurchaseadditionalequipmentandincreasecapacityforOp40Op40未做OEE的改善前，资本的投资以添购新设备增加产能是必需的OEE0.780.700.450.480.770.75EXAMPLEEffectivecycletime1有效的节拍(seconds)Assessment评估

Howcanwereducetheeffectivecycletime(forexample,increasecapacity)?如何能減少有效的节拍（例如：增加产能)？1Effectivecycletime=ObservedCycleTime/OEE

有效的节拍=当前节拍/OEECycletimeadjustmentduetoOEElosses由于OEE的损失导致节拍調整ObservedCycleTime当前节拍22

Agenda

OverallEquipmentEffectiveness(OEE)WhatisOEE?

什么是OEELinkingOEEtoPerformance

链接OEE到绩效IntroductionofOEEprogram

介绍OEE程序Conclusion

结论23

23

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