aah-0617-將軍集團(tuán)設(shè)備管理金字塔匯總.ppt

建立管理的金字塔ESHTABLISHMENTOFMANAGEMENTPYRAMID陳毅力ChenYili,將軍集團(tuán)設(shè)備管理模式TheEquipmentManagementModeofGeneralTobaccoGroups,設(shè)備管理究竟追求什么？Whatdoesmaintenancepursue?最大程度最大程度的不是供的利用設(shè)備發(fā)揮設(shè)備效率人觀賞HowtousetheHowtobringthe的花瓶equipmenttofunctionofthethegreatestextent?equipmentintothefullplay?,設(shè)備的理想利用狀態(tài)TheIdealUsageofEquipment,假設(shè)存在兩個(gè)百分之百ASSUMEEXISTINGTWOONEHUNDREDPERCENT設(shè)備最長設(shè)備無停ThelongestFullefficient日歷工作機(jī)全效calendarworkingoperatingwithout時(shí)間100%100%運(yùn)行timebreakdown,追求設(shè)備時(shí)間利用率和有效作業(yè)率的乘積SEEKFORTHEPRODUCTOFUTILIZATIONANDOVERALLEFFICIENTCYOFEQUIPMENT,設(shè)備綜合效率指數(shù)=設(shè)備生產(chǎn)時(shí)間利用率X設(shè)備有效作業(yè)率ComprehensiveEquipmentEfficiencyIndex=ProductionTimeUtilizationXOverallEfficiency設(shè)備生產(chǎn)時(shí)間利用率=設(shè)備有效作業(yè)率=設(shè)備生產(chǎn)時(shí)間/日歷時(shí)間實(shí)際產(chǎn)量/理論產(chǎn)量ProductionTimeUtilization=OverallEfficiency=ProductionTime/CalendarTimeActualOutput/TheoreticalOutput,如何提高設(shè)備綜合效率指數(shù)HOWTOINCREASETHEOVERALLEFFICIENCYINDEXOFEQUIPMENT,HowtoincreaseHowtoincreasetheutilization?theefficiency?提高時(shí)間利用率提高有效作業(yè)率生產(chǎn)組織方式設(shè)備管理模式ThetypeofproductionThetypeofmaintenanceorganizationmanagement,DIFFERENTTIMEUTILIZATIONGIVESDIFFERENTDIFFERENTTYPEOFPRODUCTIONORGANIZATION不同生產(chǎn)組織方式得到不同設(shè)備生產(chǎn)時(shí)間利用率,生產(chǎn)方式全年工作每天生產(chǎn)全年生產(chǎn)折合日歷生產(chǎn)時(shí)production天數(shù)時(shí)數(shù)時(shí)數(shù)天數(shù)間利用率organizationtotaldaysworkinghrsworkinghrscalendarTimetypeinayearperdayperyeardaysUtilization單班運(yùn)行2548203284.6723.2%1shift二班生產(chǎn)254164064169.3046.4%2shifts三班生產(chǎn)254205080211.6760.0%3shifts四班三轉(zhuǎn)355207100295.8381.1%4shifts,TIMEUTILIZATIONINDIFFERENTTYPESOFORGANIZATION不同組織形式對(duì)時(shí)間利用率的影響,四班三運(yùn)轉(zhuǎn)還有優(yōu)點(diǎn)THEOTHERADVANTAGESOF4SHIFTSIN3TURNS,加速設(shè)備折舊SpeeduptheEquipmentDepreciation用電消峰填谷BalancetheElectricityConsumption鍋爐均衡運(yùn)行BoilerinaSmoothlyRunning,不同有效作業(yè)率與不同生產(chǎn)組織方式的關(guān)系DIFFERENTOEEANDPATERNOFORANIZATION以PROTOS7000支/分計(jì)算，理論年產(chǎn)量為國為73584箱,生產(chǎn)方式生產(chǎn)時(shí)間設(shè)備有效設(shè)備綜合年產(chǎn)量production利用率作業(yè)率效率指數(shù)（箱）organizationTimeOEEComprehensiveyearlyoutputtypeUtilizationEfficiencyIndex(case)單班運(yùn)行23.2%100%0.232170711shift二班生產(chǎn)46.4%100%0.464341432shifts三班生產(chǎn)60.0%90%0.540397353shifts四班三轉(zhuǎn)81.7%80%0.654481244shifts,在有效作業(yè)率下降的情況下，隨著生產(chǎn)組織形式的調(diào)整，設(shè)備綜合效率指數(shù)仍然上升。Theefficiencyindexisincreasingalongwiththealternationofproductionorganizationtype.,如何提高設(shè)備有效作業(yè)率？,Howtoincreasetheoverallequipmentefficiency?我們從以下三個(gè)方面著手。Wetakefollowing3measures.,提高有效作業(yè)率的三塊基石The3foundationstonestoincreasetheoverallequipmentefficiency,設(shè)備有效作業(yè)率OEE設(shè)備基礎(chǔ)保養(yǎng)維修模式原料對(duì)設(shè)備的適應(yīng)性BASICMAINTENANCESUITABILTYOFMAINTENANCEMODEMATERILS,設(shè)備管理的基石之一基礎(chǔ)保養(yǎng)ONEOFTHEMANAGEMENTFOUNDATIONBASICMAINTENANCE,三加一模式：三個(gè)清潔，加一個(gè)潤滑THEMODEOF3PLUS1：3CLEANINGANDALUBRICATION+,設(shè)備清潔大有文章可做MANYIMPLICATIONSINSIDECLEANING,第一是清潔，第二是清潔，第三還是清潔CLEANING，CLEANING，ANDCLEANINGAGAIN清潔意識(shí)-清潔時(shí)間-清潔得法CLEANINGIDEOLOGYCLEANINGTIMECLEANINGMETHODOLOGY,清潔就是維修,CLEANINGISMAINTENANCE,設(shè)備管理的基石之二維修模式設(shè)備終生不大修,THESECONDFOUNDATIONOFEQUIPMENTMANAGEMENTMAINTENANCEMODEGENERALOVERHAULFREEINTHEWHOLESERVICELIFEOFEQUIPMENT,濟(jì)南卷煙廠終生不大修實(shí)踐THEPRACTICEOFOVERHAULFREEMAINTENANCEINJINANCIGARETTEFACTORY怎么修？HOWTOREPAIR？,過去：二年一大修，一年一中修，半年一小修；PAST：ANOVERHAULEVERYTWO-YEAR，AMIDDLESIZEDMAINTENANCEEVERYYEAR,AMINORMAINTENANCEEVERYHALF-YEAR；現(xiàn)在：項(xiàng)修，總成維修，組件維修，目標(biāo)：保證設(shè)備終生不大修。NOW：ITEMMAINTENANCE，“ASSEMBLY”，ORCOMPONENTMAINTENANCETOENSURE“OVERHAULFREEMAINTENANCE”,設(shè)備終生不大修取得的效益THEEFFICIENCYOFOVERHAULFREEPOLICY,比較表COMPARISON設(shè)備維修方式一次費(fèi)用12年總次數(shù)總費(fèi)用EQUIPMENTMODECOST/MTIMESIN12YTOTALCOSTMK95大修160萬元6960萬元OVERHAUL1.6MILLION9.6MILLIONMK95項(xiàng)修12萬元24288萬元ITEMMAINT.0.12MILLION2.88MILLION費(fèi)用節(jié)省672萬元COSTSAVING6.72MILLION,設(shè)備管理的基石之三原輔料對(duì)設(shè)備的適應(yīng)性,THETHIRDMANAGEMENTFOUNDATIONSUITABILITYOFRAWMATERIALTOTHEEQUIPMENT,“3A”備件管理3AOrientedSparePartManagement設(shè)備-部件-零件均做A，B,C分類，得到27個(gè)類；Equipment,assemblyandpartareallclassifiedintoA,B,C,then27differentclassesaregained.劃分四個(gè)重要性等級(jí)，采用不同關(guān)鍵性級(jí)別管理；Fourimportancegradesareclassifiedandmanagedindifferentway.再按照零件消耗規(guī)律，構(gòu)造出9個(gè)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備件管理模型,最關(guān)鍵重要一般其他KEYIMPORTANTGENERALOTHER常規(guī)消耗件冗余常規(guī)模型一般消耗模型可短缺消耗模型零REGULARREGULARREDUNDANTCOMMONDIFICIENTABLEZERO短時(shí)獨(dú)立需求冗余獨(dú)立模型一般獨(dú)立模型可短缺獨(dú)立模型庫PERIODNEEDEDPERIODREDUNDANTCOMMONPERIODDIFICIENTABLEZERO缺乏相關(guān)信息冗余上下限模型一般上下限模型可短缺獨(dú)立模型存INFO.DEFICIENTREDUNDANTLIMITEDCOMMONLIMITEDDIFICIENTABLEZERO零庫存零庫存零庫存零庫存ZEROZEROZEROZERO,維修是生產(chǎn)力MAINTENANCEISPRODUCTIVITY,兩大管理理念-全員，規(guī)范,TwoGreatManagementIdeas-AllMembersParticipating&Normalization1全員化Full-staff2規(guī)范化Normalization,將軍集團(tuán)綜合一體化目標(biāo)TargetIntegration:90-38-11,90：設(shè)備有效作業(yè)率達(dá)到90%以上；OverallEquipmentEfficiencyisabove90%38：單箱卷煙消耗煙葉在38公斤以下；Thetobaccoconsumptionpercaseofcigaretteisbelow38kg.11：實(shí)現(xiàn)1機(jī)1人，1線1人操作。Eachproductionmachine(orlinesection)isoperatedbyonlyoneoperator.,管理的連鎖保證體系,THEFOURCHAINASSURANCESYSTEMSOFMANGEMENT培訓(xùn)工作設(shè)備工藝產(chǎn)品,以培訓(xùn)質(zhì)量保證工作質(zhì)量,以“教人以會(huì)”為宗旨，保證培訓(xùn)質(zhì)量；授之以魚，未若授之以漁Itisbettertoteachfishingthantogivefish.,以工作質(zhì)量保證設(shè)備質(zhì)量Toassureequipmentqualitywithworkquality,以設(shè)備質(zhì)量保證工藝質(zhì)量Toassureprocessqualitywithequipmentquality.,以工藝質(zhì)量保證產(chǎn)品質(zhì)量Toassureproductqualitywithprocessquality