设备效率定义和计算

设备效率定义和计算Definitions•OverallEquipmentEffectiveness全面的设备有效率–Ameasureoftheequipment‘seffectivenessinproducingparts.一种在生产中设备有效率的测量–Itisdeterminedbythreefactors:由三个因素决定•EquipmentAvailability设备有效性•PerformanceEfficiency性能效率•QualityRate合格率Definitions•EquipmentAvailability设备有效性Theefficiencyofthemachinewithrespecttothetimethemachinewasavailable.•PerformanceEfficiency性能效率Ameasurementofbothspeedlossesandlossesassociatedwithidlingorminorinterruptionsresultingfromblockedorstarvedconditions.•QualityRate合格率Theefficiencyofthemachinewithrespecttothenumberofdefectsproduced.Definitions•TotalAvailableTime所有的有效时间–Thetotaltimefromstartofshifttoendofshift.•PlannedDowntime计划停工时间–Thetimethemachineisdownduetocontractualbreaks.•NetAvailableTime净有效时间–Thetimetheequipmentisplannedtooperateduringtheshift.Definitions•OperatingTime操作时间–Thetimethattheequipmentactuallyoperates.•NetOperatingTime净操作时间OperatingtimelesstheStarved&Blockedtime.–Note:Starved&Blockedlossesaffectmachineperformance,notavailablity.Definitions•TotalPartsRun所有生产零件的所需时间–Thetotalnumberofpartsproducedonthemachineduringtheshift(includingdefects).•TotalDefects所有有缺陷的零件–Thetotalnumberofrejected,reworked,orscrappedpartsproducedduringtheshift.Definitions•IdealCycleTime(secondsperpart)理想的周期时间–Thelesserof(i.e.thebetterof):•Thedesigncycletimeofthemachine•Thebestcycletimeeverachievedandsustainedonthemachine•Anestimatebasedonexperiencewithsimilarmachines•ActualCycleTime实际周期时间–Thepart-to-parttimethemachineisrunningat.Definitions•BreakdownTime停顿时间–Thetotaltimethemachineisstoppedbecauseofmalfunction.故障–Includesthetimethatthemachineisbeingrepairedandtested,untilitisreadytooperate.检修和测试•SetupTime调试时间–Thetotaltimethatthemachineisstoppedtopreparetorunadifferentpartortoalterthemachinetomeetendproductspecifications.Definitions•ToolChangeTime换模时间–Thetotaltimethatthemachineisstoppedduetofailure,breakage,deterioration,orwearofamachinetool.•StopTime停顿时间–Thetotaltimethemachineisstoppedduetointerruptionsintheprocessflowrequiringoperatororjobsetterintervention.工艺流程要求Definitions•StarvedandBlockedTime饥饿和过饱时间–Thetotaltimethemachineisstoppedduetostarvedandblockedconditions.•StartupTime开机调试时间–Thetotaltimethemachineisstopped,irrespectiveofcause,duringthefirsthouroftheshift.Definitions•SpeedLosses设备速度损失(相较理想值)–Thelostproductiontimeresultingfromtheoperationoftheequipmentatlessthanidealspeed.•Idling&MinorStoppageLosses设备空转和最小停顿时间–Thelostproductionasaresultofminorinterruptionsintheprocessflow(lossesduetoStarved&Blockedconditions).SampleBaselineInputDataTotalAvailableTime1100minPlannedDowntime100minBreakdowns*100minSetup*100minToolChange*200minStops*100minStarved&Blocked*50minStartup50min*=IncludesStartupvaluesSampleBaselineInputDataTotalPartsRun350piecesTotalDefectiveParts50piecesIdealCycleTime0.5min/pieceActualCycleTime1.0min/pieceOEECalculations(LaunchPlanPage10)•NetAvailableTime=TotalAvailableTime-PlannedDowntime=1100-100=1000min•Downtime=Breakdowns+Setup+ToolChange+Stops=100+100+200+100=500min•OperatingTime=NetAvailableTime-Downtime=1000-500=500minOEECalculations•EquipmentAvailability=OperatingTime/NetAvailableTime*100=500/1000*100=50%•PerformanceEfficiency=(IdealCycleTime*TotalPartsRun)/OperatingTime*100=(0.5*350)/500*100=35%•QualityRatio=(TotalPartsRun-TotalDefectiveParts)/TotalPartsRun*100=(350-50)/350*100=85%OEECalculations•OverallEquipmentEffectiveness=EquipmentAvailability*PerformanceEfficiency*QualityRatio/10000=50*35*85/10000=15%MajorLossesCalculations-Pieces•Breakdown=Breakdowns(min)/IdealCycleTime=100/0.5=200pieces•Setup=Setup(min)/IdealCycleTime=100/0.5=200pieces•ToolChange=ToolChange(min)/IdealCycleTime=200/0.5=400piecesMajorLossesCalculations-Pieces•Stops=Stops(min)/IdealCycleTime=100/0.5=200pieces•Starved&Blocked=Starved&Blocked(min)/IdealCycleTime=50/0.5=100pieces•Startup=Startup/IdealCycleTime=50/0.5=100piecesMajorLossesCalculations•NetOperatingTime=NetAvailableTime-Downtime-Starved&Blocked=1000-500-50=450min•AverageTimePerPart=NetOperatingTime/TotalPartsRun=450/350=1.29min/pieceMajorLossesCalculations•SpeedLoss(pieces)=(NetOperatingTime/IdealCycleTime)-(NetOperatingTime/ActualCycleTime)=(450/0.5)-(450/1.0)=450pieces•SpeedLoss(time)=SpeedLoss(pieces)*IdealCycleTime=450*0.5=225min•DefectLoss(time)=TotalDefects(pieces)*ActualCycleTime=50*1=50minNote:Defectsarelossesinrealtimesotheyarecalculatedusingactualcycletime.MajorLossesCalculations•UnidentifiedLoss(time)=NetOperatingTime-(TotalPartsRun*ActualCycleTime)=450-(350*1.0)=100min•UnidentifiedLoss(pieces)=(NetOperatingTime/ActualCycleTime)-TotalPartsRun=(450/1.0)-350=100piecesMajorLossesCalculations•IdealCycleParts=NetAvailableTime/IdealCycleTime=1000/0.5=2000pieces=Breakdown+Setup+ToolChange+Stops+Starved&Blocked+SpeedLoss+Unidentified+TotalPartsRun=200+200+400+200+100+450+100+350=2000piecesMeasurablesOEECalculationWorksheetAvailabilityA.TotalScheduledTime_____minutesB.RequiredDowntime_____minutes(ContractuallyRequiredBreaks+PaidLunch)C.NetAvailableTime(A-B)_____minutesMeasurablesOEECalculationWorksheetD.AllOtherDowntime_____minutes(Breakdowns