Overall Equipment Effectiveness-05

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减少损失 Overcoming the Losses
换模与调整 Set-ups and Adjustments:
保证工模和工夹具的准确性及可重复使用 Make tooling, fixtures and jigs accurate and repeatable 建立清晰标准 – 不要依赖工人感觉和直觉 Establish clear reference points – don’t rely on operator senses or intuition 找出调整原因 – 逐个消灭它们 Understand the cause of all adjustments – eliminate them one by one 所有换模操作、工模及工夹具均要实行标准化 Create and promote standardization across all set-ups, tools, fixtures, etc.
1) 故障损失 Breakdown losses 2) 换模及调整损失 Setup & Adjustment losses 3) 暂停损失 Minor stoppage losses 4) 速度损失
停机不超过10分种, 每月不 超过1次
可用效率大于90%
Machine down no longer than 10 min less than once a month
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整体设备效率 Overall Equipment Effectiveness
六个主要损失 Six Major Losses
故障停机 Breakdowns 换模 Set-ups 调整 Adjustments
Discrete Mfg.
可用时间 – 停机时间 Availability = Available Time – Downtime 可用效率 Available Time 可用时间
换模及调整时间不超过10分 钟
Setup & Adjustment time less than 10 minutes
装模时间 – 停机时间 Loading time – Downtime 装模时间 Loading time
停机损失
每部机空闲及暂停 - 每月不 超过3次
Idling & Minor stoppages per machine- less than 3 times a month
可用时间 Available Time: 停机时间 Downtime: 机器周期时间 MCT: 操作时间 每班时间减去允许停机时间 Shift Time less allowable breaks 换模时间, 停机时间 Changeover time, Machine Downtime 机器周期时间 (时间 / 件) Machine Cycle Time (Time/part) 可用时间 – 停机时间
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减少损失 Overcoming the Losses
品质缺陷与返工 Quality Defects and Rework:
确保考虑所有原因 – 使用好的数据收集方法, 找出原因 – 画出柏拉图 Makes sure all causes are considered – use good data collection to identify causes – establish a Pareto chart 仔细观察所有制程状况 – 输入 Carefully observe all current process conditions (inputs) 将观察结果与各种原因相比较 – 找出它们之间的相互关系 Compare observations to cause factors – look for relationships of conditions to causes 在一定条件下测试新方案 – 如果存在多个变量, 使用高一层次的统计工具进 行分析和测试 Test ideas under controlled conditions – if multiple variables exist, consider higher level statistical tools for analysis and testing. 如果测试成功, 做好文件化与标准化工作 Document and standardize successful tests.
Prepared by Date
整体设备效率 Overall Equipment Effectiveness
: Vit Jiang : Jul 27, 2011
1
量度标准 Metrics
整体设备效率 Overall Equipment Effectiveness (OEE) 可用效率 Availability 性能效率 Performance 品质效率 Quality 保养效率 Maintenance Effectiveness 平均故障时间间隔 MTTF (Mean time to failure) 平均无故障时间 MTBF (Mean time between failure) 平均维修时间 MTTR (Mean time to repair)
Performance rate greater than 95%
性能效率大于95%
净操作时间 Net Operation Time
有效操作时间
Valuable Operation Time
操作速度增加15%以上 Operation speed increase 15% Speed losses or more 5) 不良品及返工损失 在制不良品小于0.1% Quality defect & Quality defects in process less rework losses than 0.1% 合格率大于99% 6) 合格率损失 Raw material yield greater Yield losses than 99%
整体设备效率 % = 可用效率 x 性能效率 x 品质效率 x 100% OEE (%) = Availability X Performance X Quality X 100%
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TPM的目的：The Aim of TPM :
改善设备运行状况 To improve the equipment operating condition 维持设备最佳性能与可靠性 To sustain equipment at an optimal level of performance & reliability 延长设备使用寿命 To lengthen the life expectancy of equipment
机器周期时间 X 已生产零件数 已生产产值 Amount Produced Performance = MCT X # Parts Produced 性能效率 Operating Time Std/hr X Operating Time(hrs) 操作时间 标准产值/小时 x 操作时间 已生产零件数 – 不良品数 / 返工数 总产值 – 不良品 / 返工产值 Quality = # of Parts Produced – Defects/Rework Amount – Defect/Rework # of Parts Produced Total Amount Produced 质量效率 已生产零件数 已生产总产值
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减少损失 Overcoming the Losses
启动损失与原料利用率损失 Start-up and Yield Losses
量化数量与形式 Quantify amount and types
确定事件发生时间与机器/模具状况 – 模具清洁、工模调整等 Determine time of occurrences and machine/tooling conditions – mold cleaned, tooling adjustments, etc. 观察流程启动 – 识别潜在原因 Observe process start-up – identify potential causes 测试各种条件, 评价测试结果 Test different conditions and evaluate results
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设备操作及六大损失 Equipment operation and six big losses 操作时间 Operation Time 装模时间 Loading Time
Downtime losses
改善目标 Improvement targets
Availability greater tha失
最佳周期时间 x 产量 Optimal cycle time X Output 操作时间 Operation time 整体合格率大于99%
Total yield greater than 99%
Quality losses 品质损失
输入数量 – 退货数量 Input – Reject 输入数量 Input
整体设备效率 = 可用效率 x 性能效率 x 整体合格率: 大于85%
Overall equipment effectiveness = Availanility X Performance 10 X Total yield Greater than 85%
整体设备效率的计算 OEE Calculation
5
减少损失 Overcoming the Losses
空闲和暂停 Idling and Minor Stoppages:
观察发生的事情 – 收集有用的数据, 时间 / 频度 / 形式等 Observe what is happening – collect useful data (when, how often, type, etc.) 检查来料及出品特性 – 产品设计问题还是机器问题? Check both incoming and outgoing characteristics of the product – product design or machine issue? 分析根本原因 – 测试解决问题方案 – 试机运转足够时间, 用于统计数据 Root cause analysis – test ideas to eliminate – run trials over long enough duration (statistically relevant trial) 根据试机情况确定最佳机器条件, 训练工人使用新的流程标准 Determine optimal machine conditions based on trial and train all operators in the new process standards.