OEE-計(jì)算教學(xué)講解課件

OEETrainingOEE培訓(xùn)1、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式2、Elementdefined各要素定義3、Pointexplain部分疑點(diǎn)解答4、CTCScalculatecurrentlyCTCS當(dāng)前計(jì)算5、Discussdifference探討各區(qū)域的計(jì)算差異6、Summary小結(jié)OEETrainingOEE培訓(xùn)1、Standardc21、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式2、Elementdefined各要素定義3、Pointexplain部分疑點(diǎn)解答4、CTCScalculatecurrentlyCTCS當(dāng)前計(jì)算5、Discussdifference探討各區(qū)域的計(jì)算差異6、Summary小結(jié)21、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式3OEE整體設(shè)備效率OverallEquipmentEffectiveness(OEE)整體設(shè)備效率（OEE）

WhatisOEE?什么是OEE?OEEisametricwhichhelpsusunderstandhowwellaline/cell/machineisperformingcomparedtodesign,bycomparingactualproductionoutputtopossibleproductionoutput.LaborisnotdirectlymeasuredaspartofOEE.OEE是一個(gè)指標(biāo)，幫助我們理解同設(shè)計(jì)相比較，一條生產(chǎn)線/單元/一臺(tái)設(shè)備的實(shí)際運(yùn)行狀況，使用實(shí)際產(chǎn)出同設(shè)計(jì)產(chǎn)出進(jìn)行對(duì)比。勞動(dòng)力不作為OEE的一部分進(jìn)行直接計(jì)算.3OEE整體設(shè)備效率OverallEquipmentE41、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式2、Elementdefined各要素定義3、Pointexplain部分疑點(diǎn)解答4、CTCScalculatecurrentlyCTCS當(dāng)前計(jì)算5、Discussdifference探討各區(qū)域的計(jì)算差異6、Summary小結(jié)41、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式NetAvailableTime凈可利用時(shí)間

5InsertPresentationName&DateHere=Timetheline/cellisplannedtooperate.(Thismaychangeweekly)=生產(chǎn)線/單元計(jì)劃運(yùn)行時(shí)間（時(shí)間可能每周變化）'=TotalScheduledTime(suchas5daysx24hours,or5daysx8hours)-PlannedDowntime總計(jì)劃時(shí)間（如5天x24小時(shí),或5天x8小時(shí)）-計(jì)劃停機(jī)時(shí)間NetAvailableTime凈可利用時(shí)間NetAvailableTime凈可利用時(shí)間

5InsePlannedDowntime計(jì)劃停機(jī)時(shí)間6InsertPresentationName&DateHerePlannedDowntime計(jì)劃停機(jī)時(shí)間'=Legallyrequiredbreaks&lunch(&someCustomer-causedD/T.Seebelow.)法律要求的休息時(shí)間和午餐時(shí)間（以及一些客戶原因造成的停機(jī)。參見以下信息）?Customerschedulereductionswhichoccur(&maintenancewhichisscheduled)inadvanceofthenormalplanninghorizon(typically1-5days,dependingonTRWplant),countasPlannedD/T.發(fā)生在正常計(jì)劃時(shí)間之前（一般情況下為1-5天，取決于TRW工廠）的客戶計(jì)劃減少（以及計(jì)劃的維修時(shí)間）被視為計(jì)劃停機(jī)時(shí)間?PlannedD/TdoesNOTincludebreaktimeifyourunthelinepartiallyorfullystaffedthroughthebreak.如果在休息時(shí)間部分運(yùn)行或全員運(yùn)行生產(chǎn)線，那么計(jì)劃停機(jī)時(shí)間不包括休息時(shí)間PlannedDowntime計(jì)劃停機(jī)時(shí)間6InsertUnplannedDowntime非計(jì)劃停機(jī)時(shí)間7InsertPresentationName&DateHere'=Timewhenline/cellisplannedtooperatebutisnotoperating.ExcludesPlannedD/T.生產(chǎn)線/單元本該按計(jì)劃運(yùn)行卻沒有運(yùn)行得時(shí)間。不包括計(jì)劃停機(jī)時(shí)間?Materialshortage,breakdowns,set-ups,&changeoverscountasUnplannedD/T(evenifthemanpowerisshiftedelsewhereintheplant,&eveniftheD/Tspansmultipleshiftsthatwereplannedtooperate).材料短缺，故障，啟動(dòng)和切換被視為計(jì)劃外停機(jī)時(shí)間（即便勞動(dòng)力被轉(zhuǎn)移到工廠的其他地方使用，或者這種停機(jī)持續(xù)了多個(gè)本該按計(jì)劃運(yùn)行的班次）?5S,TPM,morningmeetings,qualitychecks,&equipmentcalibrationcountasUnplannedD/T.

5S,TPM，早會(huì)，質(zhì)量檢查，以及設(shè)備校準(zhǔn)被視為計(jì)劃外停機(jī)時(shí)間'-Wherepossible,5S&TPMshouldbedoneduringotherUnplannedD/Tsuchasmachinebreakdowns.如有可能，5S和TPM應(yīng)在非計(jì)劃停機(jī)時(shí)間內(nèi)進(jìn)行，如機(jī)器故障。-Whenachievableinasafemanner,TPMshouldbedonewhiletheline/cellisrunning.在確保安全的情況下，如有可能，TPM應(yīng)在生產(chǎn)線/單元運(yùn)行時(shí)進(jìn)行?UnexpectedCustomerschedulereductionswhichoccurwithinthenormalplanninghorizon(typically1-5days,dependingonplant),countasUnplannedD/T.發(fā)生在正常計(jì)劃時(shí)間（一般情況下為1-5天，取決于TRW工廠）內(nèi)的非預(yù)期客戶計(jì)劃減少被視為非計(jì)劃停機(jī)時(shí)間?Foralinewhoseproductioniscontrolledbykanban,ifitisplannedtooperate&noproductionkanbanareavailabletorun,thislosttimecountsasUnplannedD/T.對(duì)于通過看板控制生產(chǎn)的生產(chǎn)線，如果計(jì)劃運(yùn)行，并且沒有生產(chǎn)看板，那么損失時(shí)間視為計(jì)劃外停機(jī)時(shí)間。UnplannedDowntime非計(jì)劃停機(jī)時(shí)間7InseIdealCycleTime理想周期時(shí)間8InsertPresentationName&DateHere'=PlannedC/T(perTRW'sLeanLineDesign)=linespeedrequiredtoproduceapart,compensatingforexpectedlossessuchaschangeovertime&machinebreakdowns.PlannedC/T≤TaktTime.計(jì)劃周期時(shí)間（根據(jù)TRW的精益生產(chǎn)線設(shè)計(jì)）=規(guī)定的生產(chǎn)線生產(chǎn)一個(gè)零件的速度，對(duì)預(yù)期的損失，如切換時(shí)間和設(shè)備故障時(shí)間進(jìn)行補(bǔ)償。計(jì)劃停機(jī)時(shí)間≤TaktTime?IdealC/TshouldmatchthePlannedC/TintheCentralQuotationApproval(CQA)/CapitalExpenditureAuthorization(CEA).在CQA/CEA中，理想周期時(shí)間應(yīng)等于計(jì)劃周期時(shí)間?IncaseswhenC/Tdoesnotmatch&furtherimprovementisnotfinanciallyfeasible,IdealC/TmaybeadjustedtothebestC/Tachieved&sustained,ifapprovalisgivenbymanagement&Finance.Thisadjustmentshalloccurnoearlierthan90daysafterlaunch.如果周期時(shí)間不相等并且無法從財(cái)務(wù)角度做改善，在獲得管理層和財(cái)務(wù)的批準(zhǔn)后，理想周期時(shí)間可以調(diào)整為可以達(dá)成和保持的最佳周期時(shí)間，此類調(diào)整需待投產(chǎn)90天后進(jìn)行。?IncaseswhenC/Timproves&issustained(e.g.formanuallines),IdealC/Tshouldbeupdatedtoreflecttheimprovement.(OEEwilldecrease,butlaborproductivitymetricswillshowtheline'scontinuousimprovement)如果周期時(shí)間有改善并且得到保持（如手工線），理想周期時(shí)間應(yīng)適時(shí)更新以反映此改善。（OEE將降低，但勞動(dòng)力效率指標(biāo)將展示出這條線的持續(xù)改善情況）?Ifalineisintentionallyslowedtoavoidover-productionorimprovetotalcost(includinglaborproductivity),usethe"slowed"C/TforOEEcalculation(butnotOEU).如果一條線刻意延長周期時(shí)間以避免過度生產(chǎn)或改善總成本（包括勞動(dòng)力效率），那么使用延長的周期時(shí)間來計(jì)算OEE（但不針對(duì)OEU）?GrindingwheeldressingtimeisincludedingrindingIdealC/T.磨削輪準(zhǔn)備時(shí)間包含在磨削的理想周期時(shí)間內(nèi)?Under-utilizationofinjectionmoldcavitiesimpactsTotalOutput&QualityParts,notIdealC/T.注塑模腔的利用不夠影響總產(chǎn)出和合格產(chǎn)品，而非理想周期時(shí)間IdealCycleTime理想周期時(shí)間8Insert9InsertPresentationName&DateHere'=TotalnumberofpartsproducedincludingScrapandRejects.總的生產(chǎn)零件數(shù)量包括廢品和不合格品TotalOutput總產(chǎn)出'=(TotalOutput)-(Scrap+Rejects)總產(chǎn)出-（廢品+不合格品）?Ifapartisrejected&physicallyremovedfromtheline,itisaQualityloss.如果一個(gè)零件不合格并從生產(chǎn)線上拿走，那么這是一個(gè)質(zhì)量損失?Ifapartisrejected,staysontheline,&isre-run,itisaPerformanceloss.如果一個(gè)零件不合格，但留在了生產(chǎn)線上并且再次生產(chǎn)，這是一個(gè)效率損失QualityParts合格產(chǎn)品9InsertPresentationName&Da10InsertPresentationName&DateHereNote:備注?OEE&2ofitsfactors(Availability&Quality)≤100%.OEE以及其中兩個(gè)要素（可利用率和質(zhì)量率）≤100%?The3rdOEEfactor,"Performance",isnormally≤100%."Performance"exceptions(>100%)areunderstood&relatedHourlyTargets/StandardTimesarereviewedtodetermineifchangesareneeded.第三個(gè)OEE要素，“效率”，通?！?00%，“效率”例外情況（>100%）得到了解，并且相關(guān)的每小時(shí)指標(biāo)/標(biāo)準(zhǔn)時(shí)間得到評(píng)估以確定是否需要變更?Beforemultiplyingthe3OEEfactors,anyOEE"Performance"factor>100%shallbereducedto100%.在將OEE三個(gè)要素相乘之前，任何>100%的OEE“效率”因素應(yīng)降低到100%10InsertPresentationName&D111、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式2、Elementdefined各要素定義3、Pointexplain部分疑點(diǎn)解答4、CTCScalculatecurrentlyCTCS當(dāng)前計(jì)算5、Discussdifference探討各區(qū)域的計(jì)算差異6、Summary小結(jié)111、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式12InsertPresentationName&DateHereAdditionalexamplesofinterpretation:一些幫助理解的例子1、Duringproduction,Performancecalculationisconsistently>100%dueto"extra"unplannedstaffinginthecell.Answer:Cellsaresometimesrunwithdifferentstaffinglevels,buteachstaffinglevelmusthaveitsownuniquelinebalance&associatedhourlytargets.(Note:Highercelloutputdoesnotnecessarilymeanbetterlaborproductivity)在生產(chǎn)過程中，效率會(huì)因?yàn)橛?jì)劃外的人員配置而持續(xù)>100%答案：單元有時(shí)候會(huì)以不同的人員配置運(yùn)行。但每一種人員配置方式都應(yīng)該有它獨(dú)特的線平衡和相關(guān)的每小時(shí)目標(biāo)。（備注：高的單元產(chǎn)出并不一定表示勞動(dòng)力效率更高）2、Amachinebreaksdown,butduetoexcesscapacity(maybewehaveextrapressesinthattonnage),wedonothavetorunovertimetomeetproduction.Answer:ThiscountsagainstOEE(Availability).一臺(tái)設(shè)備出故障，但因?yàn)楫a(chǎn)能過剩（可能有多余的壓機(jī)），因此不需要加班答案：這會(huì)降低OEE（可利用率）Aline/cellisplannedtooperate,buthighabsenteeismforcesustooperatetheline/cellshort-handedornotatall.Answer:BothcountagainstOEE.(Short-handed=Performanceloss.Notrunningatallwhenplanned=Availabilityloss.)一條線/單元計(jì)劃了生產(chǎn)，但缺勤人數(shù)很多，只能在人手不足的情況下生產(chǎn)或者不生產(chǎn)答案：兩種結(jié)果都會(huì)降低OEE（人手不足=績效損失。完全不生產(chǎn)=可利用率損失）3、DuringnormalrunningorduringTPM,aproblemisfound.Wehadplannedtooperatethemachinebutinsteadhavetoshutitdownimmediatelyfor4hourstofix.Answer:ThiscountsagainstOEE(Availability).正常生產(chǎn)過程中或TPM過程中，發(fā)現(xiàn)了一個(gè)問題。本來計(jì)劃是運(yùn)行這臺(tái)設(shè)備，結(jié)果只能停下來維修4個(gè)小時(shí)答案：這會(huì)降低OEE（可利用率）12InsertPresentationName&DAdditionalexamplesofinterpretation:一些幫助理解的例子5、DuringnormalrunningorduringTPM,aproblemisfound.Themachinehastobeshutdownlatertoday(maybe3rdshift)for4hourstofix.That"later"4hourshadbeenscheduledforproductionpertheplanestablishedatthebeginningoftheweek.Answer:ThiscountsagainstOEE(Availability).正常生產(chǎn)過程中或TPM過程中，發(fā)現(xiàn)了一個(gè)問題。設(shè)備在晚些時(shí)候（可能在第三班）停下來維修4個(gè)小時(shí)。這四個(gè)小時(shí)在本周一開始時(shí)是計(jì)劃用來生產(chǎn)的答案：這會(huì)降低OEE（可利用率）6、DuringnormalrunningorduringTPM,aproblemisfound.Themachinewillbeshutdowntomorrowfor4hourstofix.This4hourswasoriginallyplannedforproductionpertheplanestablishedatthebeginningoftheweek.Answer:ThiscountsagainstOEE(Availability).正常生產(chǎn)過程中或TPM過程中，發(fā)現(xiàn)了一個(gè)問題。設(shè)備在明天會(huì)停下來維修4個(gè)小時(shí)。這四個(gè)小時(shí)在本周一開始是計(jì)劃用來生產(chǎn)的答案：這會(huì)降低OEE（可利用率）Additionalexamplesofinterpr141、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式2、Elementdefined各要素定義3、Pointexplain部分疑點(diǎn)解答4、

CTCScalculatecurrentlyCTCS當(dāng)前計(jì)算5、Discussdifference探討各區(qū)域的計(jì)算差異6、Summary小結(jié)141、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式15InsertPresentationName&DateHereNetAvailableTime凈可利用時(shí)間:設(shè)置的480分鐘，每班planned

Downtime計(jì)劃停機(jī)時(shí)間：設(shè)置40分鐘吃飯和20分鐘休息15InsertPresentationName&D16InsertPresentationName&DateHere1、Standardcalculate標(biāo)準(zhǔn)計(jì)算公式2、Elementdefined各要素定義3、Pointexplain部分疑點(diǎn)解答4、CTCScalculatecurrentlyCTCS當(dāng)前計(jì)算5、Discussdifference探討各區(qū)域的計(jì)算差異6、Summary小結(jié)16InsertPresentationName&D17InsertPresentationName&DateHere各區(qū)域?qū)Ρ葦?shù)據(jù)

時(shí)間節(jié)點(diǎn)（點(diǎn)）休息時(shí)間（mins）吃飯時(shí)間將休息時(shí)間又計(jì)入了非計(jì)劃停機(jī)實(shí)際節(jié)拍比工藝節(jié)拍短區(qū)域Area鉗機(jī)加