设备效率定义和计算ppt课件.ppt

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1、严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。设备效率设备效率定义和计算定义和计算严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。DefinitionsOverall Equipment Effectiveness 全面的设备有效率A measure of the equipments effectiveness in producing parts.一种在生产中设备有效率的测量一种在生产中设备有效率的测量It is determined by three fact

2、ors:由三个因素决定Equipment Availability设备有效性设备有效性Performance Efficiency性能效率性能效率Quality Rate合格率合格率严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。DefinitionsEquipment Availability设备有效性设备有效性The efficiency of the machine with respect to the time the machine was available.Performance Efficiency性能效率性能效

3、率A measurement of both speed losses and losses associated with idling or minor interruptions resulting from blocked or starved conditions.Quality Rate合格率合格率The efficiency of the machine with respect to the number of defects produced.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Definitions

4、Total Available Time 所有的有效时间所有的有效时间The total time from start of shift to end of shift.Planned Downtime 计划停工时间计划停工时间The time the machine is down due to contractual breaks.Net Available Time 净净有效时间有效时间The time the equipment is planned to operate during the shift.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、

5、汇报并处理各类违纪行为或突发事件。DefinitionsOperating Time 操作时间操作时间The time that the equipment actually operates.Net Operating Time 净操作时间操作时间Operating time less the Starved&Blocked time.Note:Starved&Blocked losses affect machine performance,not availablity.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Def

6、initionsTotal Parts Run 所有生产零件的所需时间所有生产零件的所需时间The total number of parts produced on the machine during the shift(including defects).Total Defects所有有缺陷的零件所有有缺陷的零件The total number of rejected,reworked,or scrapped parts produced during the shift.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。D

7、efinitionsIdeal Cycle Time(seconds per part)理想的周期时间理想的周期时间The lesser of(i.e.the better of):The design cycle time of the machineThe best cycle time ever achieved and sustained on the machineAn estimate based on experience with similar machinesActual Cycle Time 实际实际周期时间周期时间The part-to-part time the ma

8、chine is running at.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。DefinitionsBreakdown Time 停顿时间停顿时间The total time the machine is stopped because of malfunction.故障故障Includes the time that the machine is being repaired and tested,until it is ready to operate.检修和测试检修和测试Setup Time 调试时间调试时间The

9、 total time that the machine is stopped to prepare to run a different part or to alter the machine to meet end product specifications.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。DefinitionsTool Change Time 换模时间换模时间The total time that the machine is stopped due to failure,breakage,deterio

10、ration,or wear of a machine tool.Stop Time 停顿时间停顿时间The total time the machine is stopped due to interruptions in the process flow requiring operator or job setter intervention.工艺流程要求工艺流程要求严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。DefinitionsStarved and Blocked Time 饥饿和过饱时间The total tim

11、e the machine is stopped due to starved and blocked conditions.Startup Time 开机调试时间The total time the machine is stopped,irrespective of cause,during the first hour of the shift.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。DefinitionsSpeed Losses 设备速度损失(相较理想值)The lost production time resul

12、ting from the operation of the equipment at less than ideal speed.Idling&Minor Stoppage Losses 设备空转和最小停顿时间The lost production as a result of minor interruptions in the process flow(losses due to Starved&Blocked conditions).严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Sample Baseline Input

13、 DataTotal Available Time1100 minPlanned Downtime 100 minBreakdowns*100 minSetup*100 minTool Change*200 minStops*100 min Starved&Blocked*50 minStartup 50 min*=Includes Startup values严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Sample Baseline Input DataTotal Parts Run 350 piecesTotal Defe

14、ctive Parts 50 piecesIdeal Cycle Time 0.5 min/pieceActual Cycle Time 1.0 min/piece严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。OEE Calculations(Launch Plan Page 10)Net Available Time=Total Available Time-Planned Downtime=1100-100=1000 minDowntime=Breakdowns+Setup+Tool Change+Stops=100+100

15、+200+100 =500 minOperating Time=Net Available Time-Downtime=1000-500 =500 min 严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。OEE CalculationsEquipment Availability=Operating Time/Net Available Time*100=500/1000*100 =50%Performance Efficiency=(Ideal Cycle Time*Total Parts Run)/Operating Time

16、*100=(0.5*350)/500*100 =35%Quality Ratio=(Total Parts Run-Total Defective Parts)/Total Parts Run*100=(350-50)/350*100=85%严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。OEE CalculationsOverall Equipment Effectiveness=Equipment Availability*Performance Efficiency*Quality Ratio/10000=50*35*85/

17、10000 =15%严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Major Losses Calculations-PiecesBreakdown=Breakdowns(min)/Ideal Cycle Time=100/0.5=200 piecesSetup=Setup(min)/Ideal Cycle Time=100/0.5=200 piecesTool Change=Tool Change(min)/Ideal Cycle Time=200/0.5=400 pieces严格执行突发事件上报制度、校外活动报批制度等相关规

18、章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Major Losses Calculations-PiecesStops=Stops(min)/Ideal Cycle Time=100/0.5=200 piecesStarved&Blocked=Starved&Blocked(min)/Ideal Cycle Time=50/0.5=100 piecesStartup=Startup/Ideal Cycle Time =50/0.5=100 pieces严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Major L

19、osses CalculationsNet Operating Time=Net Available Time-Downtime-Starved&Blocked=1000-500-50 =450 minAverage Time Per Part=Net Operating Time/Total Parts Run=450/350 =1.29 min/piece严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Major Losses CalculationsSpeed Loss(pieces)=(Net Operating Time

20、/Ideal Cycle Time)-(Net Operating Time/Actual Cycle Time)=(450/0.5)-(450/1.0)=450 piecesSpeed Loss(time)=Speed Loss(pieces)*Ideal Cycle Time=450*0.5 =225 minDefect Loss(time)=Total Defects(pieces)*Actual Cycle Time=50*1 =50 minNote:Defects are losses in real time so they are calculated using actual

21、cycle time.严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Major Losses CalculationsUnidentified Loss(time)=Net Operating Time-(Total Parts Run*Actual Cycle Time)=450-(350*1.0)=100 minUnidentified Loss(pieces)=(Net Operating Time/Actual Cycle Time)-Total Parts Run=(450/1.0)-350 =100 pieces严格

22、执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Major Losses CalculationsIdeal Cycle Parts=Net Available Time/Ideal Cycle Time=1000/0.5 =2000 pieces=Breakdown+Setup+Tool Change+Stops+Starved&Blocked+Speed Loss+Unidentified+Total Parts Run=200+200+400+200+100+450+100+350=2000 pieces严格执行突发事件上报制度

23、、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Measurables OEE Calculation WorksheetAvailabilityA.Total Scheduled Time _minutesB.Required Downtime _minutes (Contractually Required Breaks +Paid Lunch)C.Net Available Time(A-B)_minutes严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Measurables OEE

24、 Calculation WorksheetD.All Other Downtime _minutes (Breakdowns+Setups&Adjustments+Tool Changes+Minor Stoppages+Meeting+Scheduled Maintenance)E.Operating Time(C-D)_minutesF.Availability(E/C)_%严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Measurables OEE Calculation WorksheetPerformance Eff

25、iciencyG.Total Parts Run _partsH.Ideal Cycle Time_min/partJ.Performance Efficiency (H*G/E)_%严格执行突发事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Measurables OEE Calculation WorksheetQuality RateK.Total Defects _partsL.Quality Rate(G-K/G)_%M.Overall Equipment Effectiveness (F*J*L)_%严格执行突发事件上报制度、校外

26、活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Mapping MeasurablesTermMeasurables TermTotal Available Time.Total Scheduled TimePlanned Downtime.Contractually Required DowntimeSetup Time.Setup&Adjustment LossesTool Change Time.Tooling LossesStop Time.Documented Minor Stoppage Losses严格执行突发事件上报制度、校外活动报批制度等相关

27、规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。Mapping MeasurablesPlanned Downtime Definition:MeasurablesPlanned Downtime=meetings and planned maintenance and is included in Downtime.OEE V3.3Does not account for meetings and planned maintenance.This can be recorded as a parameter under any downtime category.严格执行突发

28、事件上报制度、校外活动报批制度等相关规章制度。做到及时发现、制止、汇报并处理各类违纪行为或突发事件。EquipmentSeven MajorLossesOEE Term Total Available/Running Time(Production Shift Start to Shift End Time)Net Available Time/Loading Time Planned Down TimeOperating Time Downtime LossNet Operating SpeedTime LossesValuable Operating Defect Time Losses7.Defects5.Reduced Speed6.Idling&minor stops1.Breakdown2.Tool Change3.Setup&Adj.4.StopsQUALITYPERFORMANCEAVAILABILITY