【正文】 ? The effectiveness of work group future state actions should be reflected by an improvement in these metrics 價(jià)值流圖析 以益處 *價(jià)值流圖 析 是一種完整且 有 系統(tǒng) 性 的方法 *使 用價(jià)值流圖析之意義是 可 在巨觀的大范圍 下作業(yè)。 *從一個(gè)整體產(chǎn)品價(jià)值流可將各獨(dú)立工程放大作細(xì)部分析或拓展到工廠以外的價(jià)值流圖分析 價(jià)值流圖繪制 出貨作 觀察了解制程 的流動(dòng) 和順序。 作業(yè)時(shí)間 Performance Efficiency = Ideal Cycle time X Total Parts Run Operating Time OEE Formulas 計(jì)算 ? .作業(yè)性能效率 Performance Efficiency ? .理想周期時(shí)間 Ideal Cycle Time= 生產(chǎn) 一 產(chǎn)品使用規(guī)定工具的設(shè)計(jì)（工程標(biāo)準(zhǔn) )週 期 率或設(shè)計(jì)的線末率 /制程的生產(chǎn)速度 The designed (engineering standard) cycle rate of the equipment for a product using specific tooling, or the designed end line rate /line speed of the process .能于最佳時(shí)間完成單一生產(chǎn) 件 的時(shí)間 =最小時(shí)間值 衡量指標(biāo) OEE 衡量指標(biāo) OEE OEE Formulas 計(jì)算 ? .作業(yè)性能效率 Performance Efficiency ? .總件數(shù) 等於 全部生產(chǎn)件數(shù) （包含好的與不好的 ） Total Parts run equals the total number of parts produced (including good and bad ) 衡量指標(biāo) OEE ? OEE Formulas 計(jì)算 ? .品質(zhì)率 Quality 品質(zhì) =總件數(shù) 總不良件數(shù) Total Parts Run – Total Defects Total Parts Run Quality = *基本上就是首次合格率 衡量指標(biāo) OEE OEE Formulas 計(jì)算 ? .品質(zhì)率 Quality ? .關(guān)于總不良 數(shù) 等于拒收，修理，報(bào)廢件數(shù) Where total defects Equals the number of rejected rework scrapped parts 衡量指標(biāo) OEE OEE Formulas 計(jì)算 ? .品質(zhì)率 Quality ? .如果總不良 數(shù) 能被降低 品質(zhì)率價(jià)值將增加 OEE將提升 if the number of total defects can reduced the quality rate value will increase and OEE will improve 衡量指標(biāo) OEE 如何做 How to do ? .OEE 必須 備妥 量測(cè)設(shè)備 在作業(yè)制約 ? .數(shù)據(jù) 需 收集班與產(chǎn)品或工作 適 當(dāng)時(shí) ? .OEE數(shù)據(jù)必須每日檢討及傾向加班 ? .以鑒定改善機(jī)會(huì)與驗(yàn)證制程變更效率 ? .OEE數(shù)據(jù)不適用在比較工廠間績(jī)效 ? .許多變數(shù)存在 於 自然環(huán)境設(shè)備規(guī)劃及機(jī)械 ? .個(gè)別制程以比較 於 合理的基礎(chǔ) ? 時(shí)間嫁動(dòng)率 Availability Total schedule time = 720 (including overtime) Required down time = 30+30 60 lunch + breaks Net available time = 72060 660 All other downtime (machine downtime and die change ) Operating time = 66090 570 Availability = 570/660 時(shí)間嫁動(dòng)率 Availability % ? 作業(yè)性能效率 Performance Efficiency Ideal cycle time = Total parts run = 1440 Operating time = 570min Performance Efficiency = 作業(yè)性能效率 Performance Efficiency % ? 品質(zhì)率 Quality Rate Total parts run = 1440 Rework = 50 Scrap = 40 Quality Rate =1440(50+40)/1440 品質(zhì)率 Quality Rate % ? 總合效率 Overall Equipment Effectiveness Availability 時(shí)間嫁動(dòng)率 % Performance 作業(yè) 性能效率 % Quality Rate 品質(zhì)率 % Overall Equipment Effectiveness . 總合效率 OEE % 參考資料來(lái)源 : ? .Ford SiteFocused Lean Deployment ? .Ford Lio Ho 精實(shí)生產(chǎn) ? .Ford Lio Ho FPS ? 後拉式訂購(gòu)生產(chǎn) ?各製程與正確訂購(gòu) 同步 (期 )後拉看板 (或容器 )生產(chǎn) ? 各製程為單位之現(xiàn)場(chǎng)人員以看板張數(shù)目視方式來(lái)調(diào)節(jié)生產(chǎn)量及生產(chǎn)順序 A D C B A D B C 原物料區(qū) 成品區(qū) 前工程 後工程 A B C D 出貨 D C B A D C B A D B A 半成品區(qū) B 訂購(gòu)生產(chǎn) (Just In Time及時(shí)生產(chǎn) ): 只生產(chǎn)顧客需要的產(chǎn)品順序及數(shù)量 確定訂購(gòu)交期出貨 OEE (Constraint) 48 66 81 86 83 75 0 50 100 1 2 3 4 5 6 Month OEE % OEE = 稼動(dòng)率 x 性能 (作業(yè) )效率 x 良品率 對(duì)象 : 瓶頸工程 /產(chǎn)能較不足之工程 稼動(dòng)率 性能效率 良品率 ?生產(chǎn)總數(shù) ?良品數(shù) ?不良品數(shù) ?作業(yè)紀(jì)律 ?小的作業(yè)等待或中止 ?換模換線時(shí)間 。 計(jì)劃生產(chǎn)數(shù) = 數(shù)量績(jī)效 BTS Formulas 數(shù)量績(jī)效算 衡量指標(biāo) BTS ? .實(shí)際數(shù)量 合於 一個(gè)給定的產(chǎn)品別的 數(shù) 量生產(chǎn)產(chǎn)出 .在給定的天（時(shí)間）及排序數(shù)量等 於 給定的產(chǎn)品別排序的數(shù)量 ? .這一計(jì)算的結(jié)果是一百分比 ? .Where Actual Units equals units of a given product produced (off the end of the line) on a given day and scheduled Units equals units of a given product scheduled .The result of this calculation is a percentage. BTS Formulas 數(shù)量績(jī)效計(jì)算 衡量指標(biāo) BTS ? 混和績(jī)效 =混合生產(chǎn)實(shí)際數(shù)低于實(shí)際生產(chǎn)或排序計(jì)劃數(shù) ? Mix Performance = ? Actual Number of Units Built to Mix Lower of Actual Units Produced or Schedule. BTS Formulas 混合績(jī)效計(jì)算 實(shí)際依照排序生產(chǎn)數(shù) 排序計(jì)劃數(shù) =混合績(jī) 效 衡量指標(biāo) BTS ? BTS 混合績(jī)效 .BTM 實(shí)際數(shù)量 合 于生產(chǎn)數(shù)是在日生產(chǎn)排序（無(wú)超量生產(chǎn)）以實(shí)際數(shù)量生產(chǎn)或 實(shí)際 排序數(shù)量任何一低的值計(jì)算 Where Actual Units BTM equals the number of units build that are included in the daily production schedule (no overbuilds). Use actual units produced or actual units scheduled, whichever is lower to perform the calculation. 衡量指標(biāo) BTS ? BTS 混合績(jī)效 ? .如果 BTM實(shí)際數(shù)量能夠被提升，則混合績(jī)效價(jià)值將增進(jìn)及 BTS將改善 ? If the Actual Number of Units BTM can be , the Mix Performance value will increase and BTM will improve 衡量指標(biāo) BTS ? BTS Formulas 順序績(jī)效計(jì)算 順序績(jī)效 Sequence Performance = 依排序生產(chǎn)的實(shí)際數(shù)量 /實(shí)際混合量 Actual Number of Units Build to Sequence Sequence Performance 衡量指標(biāo) BTS BTS 順序績(jī)效 ? .實(shí)際依順序數(shù)量 (BTS)等 於 給定日排程順序指示的生產(chǎn)數(shù)量（謹(jǐn)首先完成排程序之前多數(shù)的數(shù)量） Where Actual Number of Units BTS equals the number of units built on a given day in the schedule order (only units after the first having a sequence number larger than all predecessors). 衡量指標(biāo) BTS BTS 序列績(jī)效 ? .如果 BTS實(shí)際數(shù)能被提高 .序列績(jī)效值將提升 .BTS ? 將 獲得改善 ? If the Actual Number of Units BTS can be increased, the Sequence Performance Value will increase and the BTS will improve. 衡量指標(biāo) BTS ? 計(jì)算例 ? 產(chǎn)品 A B ? 計(jì)劃 5 5 ? 實(shí)際 7 4 (順序： .) ? 數(shù)量績(jī)效 = 11/(5+5)+1 ? 混合績(jī)效 = (5+4)/10= ? 順序績(jī)效 = 6/9= ? 序列績(jī)效 BTS = = 衡量指標(biāo) BTS ? .如何做好工廠施行 BTS展現(xiàn)計(jì)劃到生產(chǎn)什么是 顧客想要的在適切序列與混合 ? Build to schedule reveals how well a plant executes plans to produce what customer what, in the proper sequence and mix ? .在我的區(qū)域執(zhí)行是 ? Implications for our area are: 1. 設(shè)備總和效率 OEE Overall Equi