精益生产-设备利用率

TheSixBigEquipmentLosses设备的六大损失TheSixBigEquipmentLosses

设备的六大损失Breakdowns故障停工Set-upandadjustments架模和调整Idlingandminorstoppages闲置(空转)和不严重的中断Speedlosses无法全速运转Start-up/yieldlosses(reducedyieldbetweenmachinestart-upandstableproduction)起动/生产损失(机器起动到稳定生产之间的产量缩减)Qualitydefectsandrework报废和重工TheSixBigEquipmentLosses设备的六大损失Breakdowns故障停工Thetimethatislostforproductionduetoequipmentfailures.由于机器故障而损失了生产时间Howmanyhoursamonthislostduetobreakdowns?每个月因机器故障而损失了多少小时?Isitnormaltofightthebreakdownfires?紧急处理机器故障是属于正常的情况吗?Howoftendowehavebreakdownsduetoincorrectcare?因为不正确的照顾而产生的故障频率有多高?TypesofBreakdowns故障的型式FunctionLoss(sporadic)

FunctionReduction(chronic)丧失功能(偶发性)功能降低(习惯性)SuddenFailures突然失效Hidden隐藏的Random无规则的Expected/ignored预料中的/被忽视Visible看得见Minorimpact影响较小ChronicSporadicTheSixBigEquipmentLosses

设备的六大损失Set-upandadjustments架模和调整Set-uplossesarethelossesoftimeduetothephysicalchangingoftooling,fixturesordies.架模损失是因为实际更换刀具、型规或模子而产生的时间损失Adjustmentlossesaretheadditionaltimeittakes,usuallyafteraset-up,to“adjust”theequipmenttoensurethatwehaveanacceptablepart.调整损失通常是在架模之后,为了确保产出良品而额外耗用的调整设备时间TheSixBigEquipmentLosses

设备的六大损失Idlingandminorstoppages空转和不严重的中断Arethelosseswhenwehavesmallproblemse.g.apartgetsstuckinthemachine,orotherminorproblemsthatdon’trequireamechanic.这类损失是起因于小问题，如：零件卡在机器上或是其它不需要修理人员的次要问题TheSixBigEquipmentLosses

设备的六大损失Speedlosses无法全速运转Aretheresultofnotbeingabletorunatdesignorapplicationspeed.因下列问题造成无法依照设计或规定的速度运转:Oldwornmachine老旧损耗的机器Loosedrivebelts皮带松动Whatisthedesign/applicationspeed?设计/规定的速度是多少?Nevertestedatthedesign/applicationspeed从未测试能否以设计/规定运转Start-up/yieldlosses(reducedyieldbetweenmachinestart-upandstableproduction)起动/生产损失(机器起动到稳定生产之间的产量缩减)Thesetypesoflossescanresultforthesamereasonasadjustmentandset-uplosses.这一类的损失可能与调整和架模损失具有相同的起因Thetimeittakestocorrectdefectscausedbytooling,warm-up,orotherstart-upissues.为了改正由于加工、暖机或其它启动原因造成的不良品所耗用的时间TheSixBigEquipmentLosses

设备的六大损失Qualitydefectsandrework报废和重工Ingeneralthisistheresultofproducingdefectivepartsduetoanadjustment,fixture,measurementsystemerror.通常是由于调整、型规、量测系统错误而产出不良品TheSixBigEquipmentLosses

设备的六大损失OverallEquipmentEffectiveness总体设备有效率SkipSectionOverallEquipmentEffectiveness总体体设设备备有有效效率率Ameasureofvalue-addedtoproductionthroughequipment.一种种对对设设备备加加值值生生产产的的评评量量方方式式Improvingtheequipment'stotalavailabilityandproductivity.增进进设设备备的的总总体体可可用用力力和和生生产产力力Reducingdefectswhilestabilizingandimprovingquality.当生生产产稳稳定定时时可可减减少少不不良良品品并并改改善善品品质质Equipment設備Material材料加值$$$$$HowLossesAffectProduction损耗如何何影响生生产HoursAvailableperDay=8.5每日可用用时间ScheduleWorkTime=8Hrs排程工作作时间ScheduleTime=ScheduledWorkHours*60Minutes排程时间间=排排程工工作时间间*60分分钟Notscheduled30min.未排程时时间30分钟ScheduleTime=8hours*60minutes=480minutes排程时间间=8小小时*60分钟钟=480分钟Availability可用率RunningTime=Scheduletime-DowntimeLosses运转时间间=排排程时时间-停工工损失Availability=RunningTime=480-85=395运转时间间=480-85=395Availability=Notscheduled30min.未排程时时间30分钟ScheduleTimeTimetheMachineisinaRunningMode排程时间间机器在运运转状态态的时间间DowntimeLosses85min停工时间间损失85分钟RunningTimeScheduleTime运转时间间排程时时间可用率=395480=82%可用率=395480=82%Performance效能Notscheduled30min.未排程時間30分鐘NetActualOutput淨實際產量產DowntimeLosses85min停工損失85分鐘PerformanceLoss303效能損失303件Performance效能=实际产量量目标产产量ActualOutput=ActualNumberofPartsProduced实际产量量=实实际生生产数量量ActualOutput=1,277TargetOutput=IdealCycleTime*RunTime目标产量量=理理想周周期时间间*运运转时时间TargetOutput=4parts/min*395=1,580PerformanceLoss效能损失失=1,580–1,277=303=81%Performance效能=1,2771,580QualityRate品质良率率GoodOutput=actualoutput––quality/defectslosses良品产量量=实实际产产量––品质质损失Qualityrate品质良率率=良品产量量实际产量量GoodOutput=1,277–20=1,257=98%Notscheduled30min.未排程时时间30分钟ActualOutput实际产量量DowntimeLosses85min停工损失失85分钟PerformanceLoss303效能损失失303件QQualityrate品质良率率=1,2771,257OverallEquipmentEffectiveness整体设备备有效率率GoodOutput良品产量TotalEquipmentEfficiencyLoss整体设备效率损失OEE=OverallEquipmentEffectivenessOEE=AvailabilityRatexPerformanceRatexQualityRate可用率效效能能比率品品质良良率OEE=82%x81%x98%=65%OverallEquipmentEffectiveness整体设设备有效效率AppendixASampleForms附件A表格范例例NumberOilType種類Name名稱Supplier1Spindle主轴Yelocite#6Mobil美孚2Hydraulic液压NutoH-46Exxon埃克森3Way槽Febris-K68Exxon埃克森4Cutting切削SoleneS2138Solene530WSAENon-DetergentBoyln6Gear齿轮7Grease润滑油8Compressor压缩机ATFDextronIIExxon埃克森9Quench熄灭10RustPreventive防锈11AirLineLube空气管道润滑油RegalR&O32Texico德士古12CollantCinbol3202Houton13CombHyd&Way梳齿液压槽Lubeway1706SunOil太阳石油14NorthfieldChuck北田卡盘E-6Oil15WayLube槽润滑油

(CNC)VactraOil#2Mobil美孚16BarOil钎杆油DTEHeavyMobil美孚OilCodes油料代碼ProgressMeasurementForm进度量测测表Thefollowingpagehasthisformthatcanbeprintedandlaminatedtobepostedonthemachine.下下一页也也有这张表表格可以以复印、、分层以以粘贴在在机器上上。CompletedStepFormsThefollowingpagehasthisformsthatcanbeprintedandlaminatedtobepostedonthemachine.UsevelcrotoattachthesetotheProgressMeasurementform.Also,thepassedlabelcanberemovedifnecessary.