關鍵績效(KPI)指標--培訓課件.ppt

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KeyPerformanceIndicators–Training關鍵績效指標——培訓 TheNeedtoMeasure衡量的必要性Tounderstandthecurrentsituation了解現(xiàn)狀Toidentifythefocusareasforimprovement確定需要改進的關鍵區(qū)域Toidentifytheimprovementtarget確定改進目標Toidentifytheimpactofimprovementactivity確認改善行動的影響Toensuresustainabilityanddrivefurthercontinuousimprovementactivities確保持續(xù)性并深入推動持續(xù)改進行動Whydoweneedtomeasure?為什么要進行衡量VisualFactoryWasteelimination&StandardWorkSafetyProductiveMaintenanceQualityDemandFlowContinuousImprovementWorkinginTeamsLeadershipPeopleDevelopment&Involvement2 KeyPerformanceIndicators(KPI’s)關鍵業(yè)績指標Key圖解:StrongCorrelation.關系密切SomeCorrelation少許聯(lián)系EASURE衡量標準QUALITY質(zhì)量COST琛本DELIVERY交貨SAFETY安全BBRIVIATION縮寫Safety安全TotalCaseIncidentRate總計事故發(fā)生率TCIRProductivity生產(chǎn)率LabourProductivity人工效率LPProductionQuality生產(chǎn)質(zhì)量NotRightFirstTime一交不合格率NRFTProductQuality產(chǎn)品質(zhì)量ServiceCallRate電話投訴率（社會返修率）SCRProductionDelivery交貨DeliveryScheduleAchievement按時交貨率DSAProductionInventories生產(chǎn)庫存StockTurnsWIP&Supplies在制品&物料庫存周轉(zhuǎn)率STWSWarehouseInventories倉庫存貨StockTurnsFinishedGoods成品庫存周轉(zhuǎn)率STFGConversionCosts加工成本ConversionCostperProduct單臺加工成本CCPPEquipmentEfficiency設備效率OverallEquipmentEfficiency設備綜合利用率OEEProductionEfficiency生產(chǎn)效率DisruptionFreePerformance無中斷運行DFP3 TotalCasesIncidentRate總計事故發(fā)生率AmeasureofSafetyconsideringworkplaceinjuriesinrelationtohoursworked.與工作時間相關的工傷方面的安全測定標準TCIR=Annualtotalno.ofhoursworked200000(hrs)×annualno.ofrecordableaccidentsincurred200000（小時）×年度記錄在案的事故發(fā)生數(shù)量年度總工時Unit:[rec.acc./100workers/year]單位:（事故記錄數(shù)量/100個工人/每年）200000=100workers×50weeks×40hoursperweek200000=100個工人×50周×每周40小時Recordableaccidents記錄在案的事故Annualnumberofrecordableaccidentsincurred年度記錄在案的事故發(fā)生數(shù)量Annualtotalnumberofhoursworked年度總工時DataRequired:所需數(shù)據(jù)：4 LabourProductivity人工效率Ameasureoftheratiobetweengoodunitsmadeandthedirectandindirectoperatorhoursusedtomakethem.合格品與對應的直接及間接人工工時之間的比值測定標準LP=Numberofdirectandindirectpaidoperatorhours直接及間接人工工時TotalquantityofFGunitsproduced成品生產(chǎn)總量Unit:[prod/hour]單位：（產(chǎn)品臺數(shù)/小時）FG=FinishedGoodunit.FG=成品臺數(shù)DataRequired所需數(shù)據(jù)：TotalquantityofFGproduced成品生產(chǎn)總量Numberofdirectandindirectpaidoperatorhours直接和間接人工工時5 NotRightFirstTime一交不合格率Ameasureofthequalityofaproduct/processabilitytomatchthespecification產(chǎn)品質(zhì)量/工藝能力與規(guī)范的匹配性的測定標準Totalquantityofunitsproduced生產(chǎn)總臺數(shù)Numberofdefectiveunits缺陷臺數(shù)NRFT=×1million一百萬Unit:[partspermillion,ppm]單位：（百萬分率，PPM）DataRequired所需數(shù)據(jù)：Noofunitsproduced生產(chǎn)臺數(shù)Noofunitsscrapped報廢臺數(shù)Noofunitsreworked返修臺數(shù)6 SCR電話投訴率（社會返修率）ServiceCallRateSCR=NumberofFGunitsrepairedbyAfterSalesService售后服務提供的成品維修數(shù)量TotalquantityofFGunitssold成品銷售總量ProductQualityismeasuredthroughServiceCallRateasalreadyinuse通過現(xiàn)有的SCR來衡量產(chǎn)品質(zhì)量Unit:[%]單位：（%）DataRequired:所需數(shù)據(jù)Nooffinishedgoodunitssold成品銷售總量NooffinishedgoodunitsrepairedbyAfterSalesService售后服務提供的成品維修數(shù)量FG=FinishedGoodunit.FG=成品臺數(shù)7 DeliveryScheduleAchievement按時交貨率Ameasureofhowwellasuppliermatchesthedeliveryrequirementsaccordingtoafrozenplan.廠家根據(jù)固定計劃完成交貨要求的測定標準Units:[Percent%]單位：(%)DataRequired:所需數(shù)據(jù)：Numberofplannedunits(Numberofplannedunitsfrozenfor5workingdays)計劃臺數(shù)（5個工作日之內(nèi)的固定計劃臺數(shù)）Numberofincorrectunits(Aunitisincorrectwhenitisnotintime,notincorrectquantity,notincorrectsequenceornotconformingtofrozenplan,differentPNCorproductionline.)生產(chǎn)誤差臺數(shù)（未及時、未按數(shù)量要求、未按正確的工序或不符合固定計劃、PNC碼不相符或生產(chǎn)線不一致的臺數(shù)）×100%No.ofplannedunits計劃生產(chǎn)臺數(shù)No.ofplannedunits–No.ofincorrectproducedunits計劃臺數(shù)–生產(chǎn)誤差臺數(shù)DSA=8 StockTurnsWip&Supplies在制品&物料存貨周轉(zhuǎn)率AmeasureofhowfrequentlytheWIP&SuppliesInventoryisturnedoverinrelationtoannualCostofMaterials.與年度材料成本相關的在制品&物料存貨周轉(zhuǎn)頻率的測定標準DataRequired:所需數(shù)據(jù)：12monthrollingperiodCostofMaterials:12個月滾動周期的材料成本12monthrollingaverageofWip&SuppliesInventoryvalue:在制品&物料存貨價值的12個月滾動平均數(shù)STWS=12monthrollingaveofWip&SuppliesInventoryvalue在制品&物料存貨12個月的滾動平均值12monthrollingperiodCostofMaterials12個月滾動周期的材料成本Unit:[frequency]單位：（頻率）9 StockTurnsFinishedGoods成品庫存周轉(zhuǎn)率AmeasureofhowfrequentlytheFGstockisturnedoverinrelationtotheannualFGsold(STK2).與年度成品銷售（STK2）相關的成本庫存周轉(zhuǎn)頻率的測定標準DataRequired:所需數(shù)據(jù)：12monthrollingperiodCostofFGsold:12個月滾動周期內(nèi)銷售的成品成本：12monthrollingaverageofFinishedGoodsInventoryvalue:成品庫存的12個月滾動平均值：STFG=12monthrollingaveofFGInventoryvalue成品庫存的12個月滾動平均值12monthrollingperiodCostofFGsold12個月滾動周期內(nèi)銷售的成品成本Unit:[frequency]單位：（頻率）10 ConversionCostPerProduct單臺加工成本Afinancialmeasurewhichrelatesthenumberofproductsproducedtothecostofproducingthem.將產(chǎn)品生產(chǎn)數(shù)量與其生產(chǎn)成本聯(lián)系起來的財務測定標準CCPP=TotalquantityofFGunitsproduced生產(chǎn)的成品總量STK1includingvariance–DMincludingvariances包括差異的STK1–包括差異的DMUnit:[€or$/product]單位：（歐元或美元/臺）FG=FinishedGoodunit.FG=成品臺數(shù)DataRequired:所需數(shù)據(jù)：TotalquantityofFGunitsproduced生產(chǎn)的成品總量STK1includingvariances包括差異的STK1RepresentsthesumofDM,DL,DL-b,ODC,FO-v,includingvariances表示包括差異的直接原材料,直接人工,直接人工福利,ODC,變動制造費用總量11 OverallEquipmentEfficiency設備綜合利用率Ameasureofhowefficientlyaprocessisproducingpartswithinthetimeitisplannedtorun對工序流程在計劃運轉(zhuǎn)時間內(nèi)生產(chǎn)零件的效率的測定標準OEE=Availability%×Performance%×Quality%OEE=利用率%×性能%×合格率%Availabilitycompareshowmuchtimetheprocesswasactuallyproducinginrelationtothetimeitwasplannedtorun利用率是實際生產(chǎn)流程時間與計劃運行時間的對比Performancecomparesthetheoreticaltimetoprocesstheproducedquantitytotheactualtimetoproducethem性能是生產(chǎn)一定數(shù)量產(chǎn)品的理論時間與實際生產(chǎn)時間的對比Qualitycomparesthenumberofpartsthatarerightfirsttmefromtheprocesswithtotalquantityofpartsprocessed合格率是加工一次合格部件數(shù)量與部件加工總量的對比DataRequired:所需數(shù)據(jù)：Rightfirsttimelevelofprocess(100%-NRFT%)加工一次合格率水平（100%-一交不合格率）Totalavailabletime總計利用時間Downtimelosses–plannedandunplanned停機時間損失–計劃的和非計劃的Actualoperatingtimetakentoproducepartsinperiod周期內(nèi)生產(chǎn)部件的實際操作時間Numberofpartsproducedinthatperiod該周期內(nèi)生產(chǎn)的部件數(shù)量Idealcycletimeforthepartthroughtheprocess該部件加工的理想周期12 OverallEquipmentEfficiency設備綜合利用率___Totalavailabletime總計利用時間Planneddowntime計劃停機時間Unplanneddowntime非計劃停機時間Totalavailabletime總計利用時間Planneddowntime計劃停機時間Availability=利用率x100%Performance=性能IdealcycletimexProcessedquantity理想周期x加工數(shù)量Actualoperatingtime實際操作時間x100%Quality=合格率Processedquantity–DefectQuantity加工數(shù)量–缺陷數(shù)量Processedquantity加工數(shù)量x100%13 OverallEquipmentEfficiency設備綜合利用率1000625250125Iplantorunamachinefor10hrs,withacycletimeof0.6min/part:PotentialOutput=1000parts.計劃讓機器運轉(zhuǎn)10小時，周替為每個零件0.6分鐘：可能的產(chǎn)量=1000個ButifIlose3hrstobreakdown,2hrstoachangeover.但如果故障停機3個小時，又花了2個小時進行設備轉(zhuǎn)換。Availability=?%Max.PossibleOutput=?parts利用率=?%最大產(chǎn)量可能=?個ButifwehavetorunslowlyduetomachineconditionandbecauseIamanewoperator,Ionlymake250partsinthe5hoursavailable.但是如果由于機器情況不得不讓其運轉(zhuǎn)速度放慢，再加上我是個新手，我只能在5個小時內(nèi)做250個零件。Performance=?%ActualOutput=250parts效能=?%實際產(chǎn)出=250個OEEconceptexample:設備綜合利用率案例：14 OverallEquipmentEfficiency設備綜合效率Andifhalfofthepartsthatwedomakerequirereworktomakethemintolerance.并且如果我們生產(chǎn)的零件有一半需要按要求返工，以使其在規(guī)定公差范圍之內(nèi)Quality=?%GoodPartsProduced=?合格率=?%生產(chǎn)的合格品=?OEE（設備綜合利用率）=?%x?%x?%?=?%100062525012515 OEEWorkedExampleOEE實例Amachineoperatesononeshiftofeighthourswith20minutesforbreaks假設一臺機器8小時單班，期間會有20分鐘計劃停機時間.Yesterdaythemachinestoppedfor20minfortooling,20minforbreakdownand20minforadjusting昨天該機器修模停了20分鐘，故障20分鐘，調(diào)試20分鐘。Allplannedmaintenanceiscarriedoutoutsidethenormalshifttime(8hours)按計劃機器維護安排在正常生產(chǎn)時間以后（8小時以后）Normalplannedoutputis460units.Yesterdaythemachinemade350partsofwhich20werescrappedand30reworked.Machinecycletimeis1minute計劃產(chǎn)量為460臺。但昨天只生產(chǎn)了350臺，其中20臺報廢，30臺返工，設備循環(huán)周期為1分鐘。WhatistheO.E.E.ofthemachine問該設備的OEE是多少？16 利用率=總可用時間–計劃停機時–非計劃停機時節(jié)x100%總可用時間–計劃停機時=480–20–60x100%(480–20)=87%運行率=理論循環(huán)時間x加工數(shù)量yx100%實際運行時間=1x350x100%400=87.5%=86%合格率=加工數(shù)量–缺陷數(shù)量x100%加工數(shù)量=350–50x100%350O.E.E.=87%x87.5%x86%=65.4%OEEWorkedExampleOEE計算舉例17 DisruptionFreePerformance無中斷運行AmeasureofProductionEfficiencytomonitordisruptionsinthemanufacturingprocess.制造流程中生產(chǎn)效率對生產(chǎn)中斷監(jiān)測的測定標準DisruptionsaremonitoredbyLostunits中斷由損失臺數(shù)監(jiān)測Lostunitsarethenumberofunitsthatwerenotproducedduetodisruptionsintheproductionflows,specifiedusingDFPcodesanddefinitionsas:損失臺數(shù)是指由于生產(chǎn)流程的中斷而未能生產(chǎn)的臺數(shù)，DFP的標準和定義如下：EI–Equipmentissues,MC–Materialcodes,QC–Qualitycontrol,PP–Peopleandprocess,RU–rampupEI–設備問題，MC–材料代碼，QC–質(zhì)量控制，PP–人和工序，RU–持續(xù)改善Unit:[%]單位：（%）FG=FinishedGoodunit.FG=成品數(shù)量DataRequirements:所需數(shù)據(jù)：TotalquantityofFGunitsproduced成品生產(chǎn)總臺數(shù)TheorecticalCapacity理論產(chǎn)能Theoreticalcapacity(100%)理論產(chǎn)能（100%）TotalquantityofFGunitsproduced成品生產(chǎn)總臺數(shù)DFP=×100%18