aah-0617-将军集团设备管理金字塔汇总.ppt

建立管理的金字塔ESHTABLISHMENTOFMANAGEMENTPYRAMID陈毅力ChenYili,将军集团设备管理模式TheEquipmentManagementModeofGeneralTobaccoGroups,设备管理究竟追求什么？Whatdoesmaintenancepursue?最大程度最大程度的不是供的利用设备发挥设备效率人观赏HowtousetheHowtobringthe的花瓶equipmenttofunctionofthethegreatestextent?equipmentintothefullplay?,设备的理想利用状态TheIdealUsageofEquipment,假设存在两个百分之百ASSUMEEXISTINGTWOONEHUNDREDPERCENT设备最长设备无停ThelongestFullefficient日历工作机全效calendarworkingoperatingwithout时间100%100%运行timebreakdown,追求设备时间利用率和有效作业率的乘积SEEKFORTHEPRODUCTOFUTILIZATIONANDOVERALLEFFICIENTCYOFEQUIPMENT,设备综合效率指数=设备生产时间利用率X设备有效作业率ComprehensiveEquipmentEfficiencyIndex=ProductionTimeUtilizationXOverallEfficiency设备生产时间利用率=设备有效作业率=设备生产时间/日历时间实际产量/理论产量ProductionTimeUtilization=OverallEfficiency=ProductionTime/CalendarTimeActualOutput/TheoreticalOutput,如何提高设备综合效率指数HOWTOINCREASETHEOVERALLEFFICIENCYINDEXOFEQUIPMENT,HowtoincreaseHowtoincreasetheutilization?theefficiency?提高时间利用率提高有效作业率生产组织方式设备管理模式ThetypeofproductionThetypeofmaintenanceorganizationmanagement,DIFFERENTTIMEUTILIZATIONGIVESDIFFERENTDIFFERENTTYPEOFPRODUCTIONORGANIZATION不同生产组织方式得到不同设备生产时间利用率,生产方式全年工作每天生产全年生产折合日历生产时production天数时数时数天数间利用率organizationtotaldaysworkinghrsworkinghrscalendarTimetypeinayearperdayperyeardaysUtilization单班运行2548203284.6723.2%1shift二班生产254164064169.3046.4%2shifts三班生产254205080211.6760.0%3shifts四班三转355207100295.8381.1%4shifts,TIMEUTILIZATIONINDIFFERENTTYPESOFORGANIZATION不同组织形式对时间利用率的影响,四班三运转还有优点THEOTHERADVANTAGESOF4SHIFTSIN3TURNS,加速设备折旧SpeeduptheEquipmentDepreciation用电消峰填谷BalancetheElectricityConsumption锅炉均衡运行BoilerinaSmoothlyRunning,不同有效作业率与不同生产组织方式的关系DIFFERENTOEEANDPATERNOFORANIZATION以PROTOS7000支/分计算，理论年产量为国为73584箱,生产方式生产时间设备有效设备综合年产量production利用率作业率效率指数（箱）organizationTimeOEEComprehensiveyearlyoutputtypeUtilizationEfficiencyIndex(case)单班运行23.2%100%0.232170711shift二班生产46.4%100%0.464341432shifts三班生产60.0%90%0.540397353shifts四班三转81.7%80%0.654481244shifts,在有效作业率下降的情况下，随着生产组织形式的调整，设备综合效率指数仍然上升。Theefficiencyindexisincreasingalongwiththealternationofproductionorganizationtype.,如何提高设备有效作业率？,Howtoincreasetheoverallequipmentefficiency?我们从以下三个方面着手。Wetakefollowing3measures.,提高有效作业率的三块基石The3foundationstonestoincreasetheoverallequipmentefficiency,设备有效作业率OEE设备基础保养维修模式原料对设备的适应性BASICMAINTENANCESUITABILTYOFMAINTENANCEMODEMATERILS,设备管理的基石之一基础保养ONEOFTHEMANAGEMENTFOUNDATIONBASICMAINTENANCE,三加一模式：三个清洁，加一个润滑THEMODEOF3PLUS1：3CLEANINGANDALUBRICATION+,设备清洁大有文章可做MANYIMPLICATIONSINSIDECLEANING,第一是清洁，第二是清洁，第三还是清洁CLEANING，CLEANING，ANDCLEANINGAGAIN清洁意识-清洁时间-清洁得法CLEANINGIDEOLOGYCLEANINGTIMECLEANINGMETHODOLOGY,清洁就是维修,CLEANINGISMAINTENANCE,设备管理的基石之二维修模式设备终生不大修,THESECONDFOUNDATIONOFEQUIPMENTMANAGEMENTMAINTENANCEMODEGENERALOVERHAULFREEINTHEWHOLESERVICELIFEOFEQUIPMENT,济南卷烟厂终生不大修实践THEPRACTICEOFOVERHAULFREEMAINTENANCEINJINANCIGARETTEFACTORY怎么修？HOWTOREPAIR？,过去：二年一大修，一年一中修，半年一小修；PAST：ANOVERHAULEVERYTWO-YEAR，AMIDDLESIZEDMAINTENANCEEVERYYEAR,AMINORMAINTENANCEEVERYHALF-YEAR；现在：项修，总成维修，组件维修，目标：保证设备终生不大修。NOW：ITEMMAINTENANCE，“ASSEMBLY”，ORCOMPONENTMAINTENANCETOENSURE“OVERHAULFREEMAINTENANCE”,设备终生不大修取得的效益THEEFFICIENCYOFOVERHAULFREEPOLICY,比较表COMPARISON设备维修方式一次费用12年总次数总费用EQUIPMENTMODECOST/MTIMESIN12YTOTALCOSTMK95大修160万元6960万元OVERHAUL1.6MILLION9.6MILLIONMK95项修12万元24288万元ITEMMAINT.0.12MILLION2.88MILLION费用节省672万元COSTSAVING6.72MILLION,设备管理的基石之三原辅料对设备的适应性,THETHIRDMANAGEMENTFOUNDATIONSUITABILITYOFRAWMATERIALTOTHEEQUIPMENT,“3A”备件管理3AOrientedSparePartManagement设备-部件-零件均做A，B,C分类，得到27个类；Equipment,assemblyandpartareallclassifiedintoA,B,C,then27differentclassesaregained.划分四个重要性等级，采用不同关键性级别管理；Fourimportancegradesareclassifiedandmanagedindifferentway.再按照零件消耗规律，构造出9个模型。Accordingtherulesofsparepartconsumption,9modelsarestructured.,AAA，AAB，AAC，ABA，ACA，ABB，ABC，ACB,ACC，BAA，BAB，BAC，BBA，BCA，BBB，BCB，BBC，BCC，CAA，CAB，CBA，CBB，CAC，CCA，CBC，CCB，CCC,Modelsof3Asparepartsmanagement3A备件管理模型,最关键重要一般其他KEYIMPORTANTGENERALOTHER常规消耗件冗余常规模型一般消耗模型可短缺消耗模型零REGULARREGULARREDUNDANTCOMMONDIFICIENTABLEZERO短时独立需求冗余独立模型一般独立模型可短缺独立模型库PERIODNEEDEDPERIODREDUNDANTCOMMONPERIODDIFICIENTABLEZERO缺乏相关信息冗余上下限模型一般上下限模型可短缺独立模型存INFO.DEFICIENTREDUNDANTLIMITEDCOMMONLIMITEDDIFICIENTABLEZERO零库存零库存零库存零库存ZEROZEROZEROZERO,维修是生产力MAINTENANCEISPRODUCTIVITY,两大管理理念-全员，规范,TwoGreatManagementIdeas-AllMembersParticipating&Normalization1全员化Full-staff2规范化Normalization,将军集团综合一体化目标TargetIntegration:90-38-11,90：设备有效作业率达到90%以上；OverallEquipmentEfficiencyisabove90%38：单箱卷烟消耗烟叶在38公斤以下；Thetobaccoconsumptionpercaseofcigaretteisbelow38kg.11：实现1机1人，1线1人操作。Eachproductionmachine(orlinesection)isoperatedbyonlyoneoperator.,管理的连锁保证体系,THEFOURCHAINASSURANCESYSTEMSOFMANGEMENT培训工作设备工艺产品,以培训质量保证工作质量,以“教人以会”为宗旨，保证培训质量；授之以鱼，未若授之以渔Itisbettertoteachfishingthantogivefish.,以工作质量保证设备质量Toassureequipmentqualitywithworkquality,以设备质量保证工艺质量Toassureprocessqualitywithequipmentquality.,以工艺质量保证产品质量Toassureproductqualitywithprocessquality