1、OEE Training OEE培训,1、Standard calculate 标准计算公式 2、Element defined 各要素定义 3、Point explain 部分疑点解答 4、 CTCS calculate currently CTCS当前计算 5、Discuss difference 探讨各区域的计算差异 6、Summary 小结,2,1、Standard calculate 标准计算公式 2、Element defined 各要素定义 3、Point explain 部分疑点解答 4、 CTCS calculate currently CTCS当前计算 5、Discuss
2、difference 探讨各区域的计算差异 6、Summary 小结,3,OEE 整体设备效率,Overall Equipment Effectiveness (OEE)整体设备效率（OEE）,What is OEE? 什么是OEE?,OEE is a metric which helps us understand how well a line/cell/machine is performing compared to design, by comparing actual production output to possible production output. Labor is
3、 not directly measured as part of OEE. OEE是一个指标，帮助我们理解同设计相比较，一条生产线/单元/一台设备的实际运行状况，使用实际产出同设计产出进行对比。劳动力不作为OEE的一部分进行直接计算.,4,1、Standard calculate 标准计算公式 2、Element defined 各要素定义 3、Point explain 部分疑点解答 4、 CTCS calculate currently CTCS当前计算 5、Discuss difference 探讨各区域的计算差异 6、Summary 小结,Net Available Time净可利用
4、时间,5,Insert Presentation Name & Date Here,= Time the line/cell is planned to operate. (This may change weekly) =生产线/单元计划运行时间（时间可能每周变化）,= Total Scheduled Time (such as 5 days x 24 hours, or 5 days x 8 hours) - Planned Downtime 总计划时间（如5天x 24 小时, 或 5 天 x 8 小时）-计划停机时间,Net Available Time 净可利用时间,Planned D
5、owntime计划停机时间,6,Insert Presentation Name & Date Here,Planned Downtime 计划停机时间,= Legally required breaks & lunch (& some Customer-caused D/T. See below.) 法律要求的休息时间和午餐时间（以及一些客户原因造成的停机。参见以下信息）, Customer schedule reductions which occur (& maintenance which is scheduled) in advance of the normal planning
6、horizon (typically 1-5 days, depending on TRW plant), count as Planned D/T. 发生在正常计划时间之前（一般情况下为1-5天，取决于TRW工厂）的客户计划减少（以及计划的维修时间）被视为计划停机时间, Planned D/T does NOT include break time if you run the line partially or fully staffed through the break. 如果在休息时间部分运行或全员运行生产线，那么计划停机时间不包括休息时间,Unplanned Downtime非计划
7、停机时间,7,Insert Presentation Name & Date Here,= Time when line/cell is planned to operate but is not operating. Excludes Planned D/T. 生产线/单元本该按计划运行却没有运行得时间。不包括计划停机时间 Material shortage, breakdowns, set-ups, & changeovers count as Unplanned D/T (even if the manpower is shifted elsewhere in the plant, &
8、even if the D/T spans multiple shifts that were planned to operate). 材料短缺，故障，启动和切换被视为计划外停机时间（即便劳动力被转移到工厂的其他地方使用，或者这种停机持续了多个本该按计划运行的班次） 5S, TPM, morning meetings, quality checks, & equipment calibration count as Unplanned D/T. 5S,TPM， 早会，质量检查，以及设备校准被视为计划外停机时间 - Where possible, 5S & TPM should be done
9、 during other Unplanned D/T such as machine breakdowns. 如有可能，5S和TPM应在非计划停机时间内进行，如机器故障。- When achievable in a safe manner, TPM should be done while the line/cell is running. 在确保安全的情况下，如有可能，TPM应在生产线/单元运行时进行 Unexpected Customer schedule reductions which occur within the normal planning horizon (typical
10、ly 1-5 days, depending on plant), count as Unplanned D/T. 发生在正常计划时间（一般情况下为1-5天，取决于TRW工厂）内的非预期客户计划减少被视为非计划停机时间 For a line whose production is controlled by kanban, if it is planned to operate & no production kanban are available to run, this lost time counts as Unplanned D/T. 对于通过看板控制生产的生产线，如果计划运行，并且
11、没有生产看板，那么损失时间视为计划外停机时间。,Ideal Cycle Time理想周期时间,8,Insert Presentation Name & Date Here,= Planned C/T (per TRWs Lean Line Design) = line speed required to produce a part, compensating for expected losses such as changeover time & machine breakdowns. Planned C/T Takt Time. 计划周期时间（根据TRW的精益生产线设计）=规定的生产线生
12、产一个零件的速度，对预期的损失，如切换时间和设备故障时间进行补偿。计划停机时间Takt Time Ideal C/T should match the Planned C/T in the Central Quotation Approval (CQA) / Capital Expenditure Authorization (CEA).在CQA/CEA中， 理想周期时间应等于计划周期时间 In cases when C/T does not match & further improvement is not financially feasible, Ideal C/T may be ad
13、justed to the best C/T achieved & sustained, if approval is given by management & Finance. This adjustment shall occur no earlier than 90 days after launch. 如果周期时间不相等并且无法从财务角度做改善，在获得管理层和财务的批准后，理想周期时间可以调整为可以达成和保持的最佳周期时间，此类调整需待投产90天后进行。 In cases when C/T improves & is sustained (e.g. for manual lines)
14、, Ideal C/T should be updated to reflect the improvement. (OEE will decrease, but labor productivity metrics will show the lines continuous improvement) 如果周期时间有改善并且得到保持（如手工线），理想周期时间应适时更新以反映此改善。（OEE将降低，但劳动力效率指标将展示出这条线的持续改善情况） If a line is intentionally slowed to avoid over-production or improve total
15、 cost (including labor productivity), use the “slowed“ C/T for OEE calculation (but not OEU). 如果一条线刻意延长周期时间以避免过度生产或改善总成本（包括劳动力效率），那么使用延长的周期时间来计算OEE（但不针对OEU） Grinding wheel dressing time is included in grinding Ideal C/T. 磨削轮准备时间包含在磨削的理想周期时间内 Under-utilization of injection mold cavities impacts Total
16、 Output & Quality Parts, not Ideal C/T. 注塑模腔的利用不够影响总产出和合格产品，而非理想周期时间,9,Insert Presentation Name & Date Here,= Total number of parts produced including Scrap and Rejects.总的生产零件数量包括废品和不合格品,Total Output总产出,= (Total Output) - (Scrap + Rejects) 总产出-（废品+不合格品）, If a part is rejected & physically removed fr
17、om the line, it is a Quality loss.如果一个零件不合格并从生产线上拿走，那么这是一个质量损失, If a part is rejected, stays on the line, & is re-run, it is a Performance loss.如果一个零件不合格，但留在了生产线上并且再次生产，这是一个效率损失,Quality Parts合格产品,10,Insert Presentation Name & Date Here,Note: 备注, OEE & 2 of its factors (Availability & Quality) 100%.
18、OEE 以及其中两个要素（可利用率和质量率） 100% The 3rd OEE factor, “Performance“, is normally 100%. “Performance“ exceptions ( 100%) are understood & related Hourly Targets / Standard Times are reviewed to determine if changes are needed. 第三个OEE要素，“效率”，通常 100%，“效率”例外情况（ 100%）得到了解，并且相关的每小时指标/标准时间得到评估以确定是否需要变更 Before mu
19、ltiplying the 3 OEE factors, any OEE “Performance“ factor 100% shall be reduced to 100%. 在将OEE三个要素相乘之前，任何 100% 的OEE“效率”因素应降低到100%,11,1、Standard calculate 标准计算公式 2、Element defined 各要素定义 3、Point explain 部分疑点解答 4、 CTCS calculate currently CTCS当前计算 5、Discuss difference 探讨各区域的计算差异 6、Summary 小结,12,Insert
20、Presentation Name & Date Here,Additional examples of interpretation:一些帮助理解的例子,1、During production, Performance calculation is consistently 100% due to “extra“ unplanned staffing in the cell. Answer: Cells are sometimes run with different staffing levels, but each staffing level must have its own uni
21、que line balance & associated hourly targets. (Note: Higher cell output does not necessarily mean better labor productivity) 在生产过程中，效率会因为计划外的人员配置而持续100%答案：单元有时候会以不同的人员配置运行。但每一种人员配置方式都应该有它独特的线平衡和相关的每小时目标。（备注：高的单元产出并不一定表示劳动力效率更高）,2、A machine breaks down, but due to excess capacity (maybe we have extra
22、 presses in that tonnage), we do not have to run overtime to meet production. Answer: This counts against OEE (Availability).一台设备出故障，但因为产能过剩（可能有多余的压机），因此不需要加班 答案：这会降低OEE（可利用率）,A line/cell is planned to operate, but high absenteeism forces us to operate the line/cell short-handed or not at all. Answe
23、r: Both count against OEE. (Short-handed = Performance loss. Not running at all when planned = Availability loss.) 一条线/单元计划了生产，但缺勤人数很多，只能在人手不足的情况下生产或者不生产 答案：两种结果都会降低OEE（人手不足=绩效损失。完全不生产=可利用率损失）,3、During normal running or during TPM, a problem is found. We had planned to operate the machine but instea
24、d have to shut it down immediately for 4 hours to fix. Answer: This counts against OEE (Availability). 正常生产过程中或TPM过程中，发现了一个问题。本来计划是运行这台设备，结果只能停下来维修4个小时 答案：这会降低OEE（可利用率）,Additional examples of interpretation:一些帮助理解的例子,5、 During normal running or during TPM, a problem is found. The machine has to be s
25、hut down later today (maybe 3rd shift) for 4 hours to fix. That “later“ 4 hours had been scheduled for production per the plan established at the beginning of the week. Answer: This counts against OEE (Availability). 正常生产过程中或TPM过程中，发现了一个问题。设备在晚些时候（可能在第三班）停下来维修4个小时。这四个小时在本周一开始时是计划用来生产的 答案：这会降低OEE（可利用
26、率）,6、 During normal running or during TPM, a problem is found. The machine will be shut down tomorrow for 4 hours to fix. This 4 hours was originally planned for production per the plan established at the beginning of the week. Answer: This counts against OEE (Availability). 正常生产过程中或TPM过程中，发现了一个问题。设
27、备在明天会停下来维修4个小时。这四个小时在本周一开始是计划用来生产的 答案：这会降低OEE（可利用率）,14,1、Standard calculate 标准计算公式 2、Element defined 各要素定义 3、Point explain 部分疑点解答 4、 CTCS calculate currently CTCS当前计算 5、Discuss difference 探讨各区域的计算差异 6、Summary 小结,15,Insert Presentation Name & Date Here,Net Available Time净可利用时间:设置的480分钟，每班,planned Dow
28、ntime计划停机时间：设置40分钟吃饭和20分钟休息,16,Insert Presentation Name & Date Here,1、Standard calculate 标准计算公式 2、Element defined 各要素定义 3、Point explain 部分疑点解答 4、 CTCS calculate currently CTCS当前计算 5、Discuss difference 探讨各区域的计算差异 6、Summary 小结,17,Insert Presentation Name & Date Here,描述 Describe,数据收集 Data,18,Insert Pre
29、sentation Name & Date Here,1、Standard calculate 标准计算公式 2、Element defined 各要素定义 3、Point explain 部分疑点解答 4、 CTCS calculate currently CTCS当前计算 5、Discuss difference 探讨各区域的计算差异 6、Need to do 需要做的工作,19,Insert Presentation Name & Date Here,统一班次理解，如0点到8点为第一班.； 统一休息时间如20分钟； 统一吃饭时间.30分钟还是40分钟？； 统一数据录入规则，如公式设置了吃
30、饭和休息时间，录入时不再计算; 多台设备的瓶颈问题确定，如钳机加的销孔; 如盘器装配区域，将防尘罩上粘贴合格证、支架螺栓上弹垫等本应由单独工位完成的工作在装配前集中完成所产生的停机时间，计算为停机待料，类似问题应计入节拍。-商讨 ,例如：盘器装配区域，将防尘罩上粘贴合格证、支架螺栓上弹垫等本应由单独工位完成的工作，在装配前集中完成所产生的停机时间，计算为停机待料，这在理解上有误，停机待料是由于材料短缺引起的停机。由于工艺部在计算节拍时，防尘罩上粘贴合格证、支架螺栓上弹垫的动作是计入工序节拍的，因此按节拍进行生产是满足要求的，没有集中提前完成而停机的必要，且防尘罩上粘贴合格证、支架螺栓上弹垫工序并非瓶颈工序。,数据收集 Data,
