【正文】 ? = 實際運行時間 /可運行時間 ? 效率 : 實際產(chǎn)量與標準產(chǎn)量的比率 ? = (實際產(chǎn)量 /小時 )/(標準產(chǎn)量 /小時 ) ? 產(chǎn)出 : 用一特定時間段的產(chǎn)量來衡量 ? = 磅 /小時 , 件數(shù) /小時 Control Total Productive Maintenance (TPM) 20 Typical Operational Process Measurements ? Utilization: The ratio of equipment actual operating time to the total available operating time ? = Actual Operating Time/Available Time ? Efficiency: The ratio of actual product produced to a standard ? = (Actual Parts/Hour)/(Standard Part/Hour) ? Output: Measure of output over a specified time period ? = lbs/hr, pieces/hr Control Total Productive Maintenance (TPM) 21 設備綜合利用率 OEE ? 設備綜合利用率（ OEE） 是衡量一臺設備按計劃速度生產(chǎn)出合格產(chǎn)品的時間占全部時間的百分比 . Control Total Productive Maintenance (TPM) 22 Overall Equipment Effectiveness ? Overall Equipment Effectiveness (OEE) is the measure of the percent of time a piece of equipment is producing quality product at the designed rate. Control Total Productive Maintenance (TPM) 23 OEE分解 :六大浪費 故障及輕微故障 使設備中斷運行的時間超過 10分鐘的故障或者中斷時間少于 10分鐘的輕微故障 . 設置時間浪費 任何與設備調(diào)整 ,裝配 ,清潔相關的作業(yè) . 機器空轉(zhuǎn)浪費 設備在運轉(zhuǎn)卻沒有用來生產(chǎn)產(chǎn)品所耗用的時間 . 速度浪費 由于設備或產(chǎn)品的異常造成設備以低于標準速度或所設定的速度運轉(zhuǎn) . 品質(zhì)原因浪費 為確保設備產(chǎn)出品的品質(zhì)而采取相關的作業(yè) (過程中檢查 ). 返工浪費 用于返修產(chǎn)品或生產(chǎn)出報廢產(chǎn)品所耗用的時間 . 可用水平 (AL) 運行水平 (OL) 質(zhì)量水平 (QL) Control Total Productive Maintenance (TPM) 24 OEE Breakdown: The Six Big Losses Breakdowns and Minor Stoppages Malfunctions causing equipment to stop processing greater than 10 minutes (breakdowns) or less than 10 minutes (minor stoppages) Setup Any activity related to equipment changeover, setup, or cleaning. Idling Time equipment is running but not producing product. Speed Losses Equipment operating at less than standard or design speed due to equipment/product abnormality Quality Factors Activities related to ensuring the quality of the product produced on the equipment (inprocess checks). Rework Losses The time taken to reprocess product or time take to produce unusable product. Availability Level (AL) Operating Level (OL) Quality Level (QL) Control Total Productive Maintenance (TPM) 25 六大浪費的識別練習 識別損失類別12345678910機器A 在下午1 點鐘完成一產(chǎn)品裝配而在下午2 : 2 7 開始另一產(chǎn)品的裝配工作現(xiàn)象由于電氣故障機器A 的運轉(zhuǎn)中斷3 1 分鐘過程中的質(zhì)量檢查耗時2 2 分鐘機器B 上的小裝置裝卸時間為4 分鐘由于機械故障機器X 運轉(zhuǎn)中斷8 分鐘機器Z 的清潔時間為4 7 分鐘工件被軋住造成機器C 中斷3 分鐘從取樣到送至實驗室耗時3 2 分鐘機器Z 返修2 0 0 個工件由于機油線路泄漏機器D 僅能以每小時加工1 0 0 片產(chǎn)品的速度運行達不到1 2 5 片的標準 S C E N A R I O L O S S I D E N T I F I C A T I O N 1. M a c h i n e A o p e r a t i o n i s i n t e r r u p t e d b y a n e l e c t r i c a l p r o b l e m f o r 3 1 m i n u t e s 由于電氣故障機器 A 的運轉(zhuǎn)中斷 31 分鐘 2. A n i n p r o c e s s q u a l i t y c h e c k t a k e s 2 2 m i n u t e s 3. L o a d u n l o a d t i m e b e t w e e n w i d g e t s o n m a c h i n e B i s 4 m i n u t e s 機器 B 上的小部件 裝卸的時 間 為 4 分鐘 4. M a c h i n e X o p e r a t i o n i s i n t e r r u p t e d o f 8 m i n u t e s d u e t o a m e c h a n i c a l p r o b l e m 由于機械故障機器 X 運轉(zhuǎn)中斷 8 分鐘 5. C l e a n i n g t i m e o n m a c h i n e Z i s 4 7 m i n u t e s 機器 Z 的清潔時間為47 分鐘 6. J a m m e d p i e c e c a u s e s m a c h i n e C s t o p p a g e o f 3 m i n u t e s 7. M a c h i n e A c o m p l e t e s a l o a d a t 1 : 0 0 p m a n d b e g i n s a n o t h e r l o a d ( d i f f e r e n t p r o d u c t ) a t 2 : 2 7 p m 8. A s a m p l e i s t a k e n a n d t r a n s p o r t e d t o t h e l a b t a k i n g 3 2 m i n u t e s 9. 2 0 0 p i e c e s a r e r e p r o c e s s e d o n m a c h i n e Z 10. M a c h i n e D r u n s a t 1 0 0 p c / h r n o t 1 2 5 p c / h r d u e t o l e a k y o i l l i n e s Control Total Productive Maintenance (TPM) 26 Six Big Losses Identification Exercise S C E N A R I O L O S S I D E N T I F I C A T I O N 1. Machi ne A op erat i on i s i nt err up t ed by an el ectr i cal probl em f or 31 mi nu t es 2. A n i n proces s qu al i t y che ck t ake s 22 mi nu t es 3. Lo ad un l oa d t i me be t w ee n w i dg et s on machi ne B i s 4 mi nu t es 4. Machi ne X op erat i on i s i nt err up t ed of 8 mi nu t es due t o a mecha ni cal probl em 5. C l ea ni ng t i me on machi ne Z i s 47 mi nu t es 6. Jammed pi ece cau ses machi ne C st op pa ge of 3 mi nu t es 7. Machi ne A pl et es a l oa d at 1: 00 pm an d be gi ns another l oa d ( di f f erent produ ct ) at 2: 27 pm 8 . A sampl e i s t ake n an d t r an spo r t ed t o t he l ab t aki ng 32 mi nu t es 9. 20 0 pi ece s are r e proces sed on machi ne Z 10. Machi ne D r un s at 10 0 pc/hr no t 12 5 pc/hr du e t o l ea ky oi l l i ne s Control Total Productive Maintenance (TPM) 27 OEE的計算原理 承載時間 (LT) 設備運轉(zhuǎn)總的可利用時間 = 40 hrs 可用水平(AL) 運行水平 (OL) 質(zhì)量水平 (QL) OEE 73% x 91% x 80% = 80% = 91% 質(zhì)量原因 機器故障及輕微故障 , 行政事務 /非作業(yè)時間 機器 設置與調(diào)整 速度損失 機器空轉(zhuǎn) 返工及 報廢 40 = 73% 40 OEE = 53% AL HRS = 40 = hrs OL HRS = = hrs QL HRS = = hrs Control Total Productive Maintenance (TPM) 28 Calculating OEE Elements Loading Time (LT) Total Hours Available for Equipment Operation = 40 hrs Availability Level (AL) Operating Level (OL) Quality Level (QL) OEE 73% x 91% x 80% = 80% = 91% Quality Factors Breakdowns Minor Stops, and Admin. Setup Speed Losses Idling Rework and Scrap 40 = 73% 40 OEE = 53% AL HRS = 40 = hrs OL HRS = = hrs QL HRS = = hrs Control Total Productive Maintenance (TPM) 29 世界級的 OEE性能水平 承載時間 (LT) 同步計劃運轉(zhuǎn)時間及生產(chǎn)性防護時