关键绩效(KPI)指标--培训课件.ppt

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KeyPerformanceIndicators–Training关键绩效指标——培训 TheNeedtoMeasure衡量的必要性Tounderstandthecurrentsituation了解现状Toidentifythefocusareasforimprovement确定需要改进的关键区域Toidentifytheimprovementtarget确定改进目标Toidentifytheimpactofimprovementactivity确认改善行动的影响Toensuresustainabilityanddrivefurthercontinuousimprovementactivities确保持续性并深入推动持续改进行动Whydoweneedtomeasure?为什么要进行衡量VisualFactoryWasteelimination&StandardWorkSafetyProductiveMaintenanceQualityDemandFlowContinuousImprovementWorkinginTeamsLeadershipPeopleDevelopment&Involvement2 KeyPerformanceIndicators(KPI’s)关键业绩指标Key图解:StrongCorrelation.关系密切SomeCorrelation少许联系EASURE衡量标准QUALITY质量COST琛本DELIVERY交货SAFETY安全BBRIVIATION缩写Safety安全TotalCaseIncidentRate总计事故发生率TCIRProductivity生产率LabourProductivity人工效率LPProductionQuality生产质量NotRightFirstTime一交不合格率NRFTProductQuality产品质量ServiceCallRate电话投诉率（社会返修率）SCRProductionDelivery交货DeliveryScheduleAchievement按时交货率DSAProductionInventories生产库存StockTurnsWIP&Supplies在制品&物料库存周转率STWSWarehouseInventories仓库存货StockTurnsFinishedGoods成品库存周转率STFGConversionCosts加工成本ConversionCostperProduct单台加工成本CCPPEquipmentEfficiency设备效率OverallEquipmentEfficiency设备综合利用率OEEProductionEfficiency生产效率DisruptionFreePerformance无中断运行DFP3 TotalCasesIncidentRate总计事故发生率AmeasureofSafetyconsideringworkplaceinjuriesinrelationtohoursworked.与工作时间相关的工伤方面的安全测定标准TCIR=Annualtotalno.ofhoursworked200000(hrs)×annualno.ofrecordableaccidentsincurred200000（小时）×年度记录在案的事故发生数量年度总工时Unit:[rec.acc./100workers/year]单位:（事故记录数量/100个工人/每年）200000=100workers×50weeks×40hoursperweek200000=100个工人×50周×每周40小时Recordableaccidents记录在案的事故Annualnumberofrecordableaccidentsincurred年度记录在案的事故发生数量Annualtotalnumberofhoursworked年度总工时DataRequired:所需数据：4 LabourProductivity人工效率Ameasureoftheratiobetweengoodunitsmadeandthedirectandindirectoperatorhoursusedtomakethem.合格品与对应的直接及间接人工工时之间的比值测定标准LP=Numberofdirectandindirectpaidoperatorhours直接及间接人工工时TotalquantityofFGunitsproduced成品生产总量Unit:[prod/hour]单位：（产品台数/小时）FG=FinishedGoodunit.FG=成品台数DataRequired所需数据：TotalquantityofFGproduced成品生产总量Numberofdirectandindirectpaidoperatorhours直接和间接人工工时5 NotRightFirstTime一交不合格率Ameasureofthequalityofaproduct/processabilitytomatchthespecification产品质量/工艺能力与规范的匹配性的测定标准Totalquantityofunitsproduced生产总台数Numberofdefectiveunits缺陷台数NRFT=×1million一百万Unit:[partspermillion,ppm]单位：（百万分率，PPM）DataRequired所需数据：Noofunitsproduced生产台数Noofunitsscrapped报废台数Noofunitsreworked返修台数6 SCR电话投诉率（社会返修率）ServiceCallRateSCR=NumberofFGunitsrepairedbyAfterSalesService售后服务提供的成品维修数量TotalquantityofFGunitssold成品销售总量ProductQualityismeasuredthroughServiceCallRateasalreadyinuse通过现有的SCR来衡量产品质量Unit:[%]单位：（%）DataRequired:所需数据Nooffinishedgoodunitssold成品销售总量NooffinishedgoodunitsrepairedbyAfterSalesService售后服务提供的成品维修数量FG=FinishedGoodunit.FG=成品台数7 DeliveryScheduleAchievement按时交货率Ameasureofhowwellasuppliermatchesthedeliveryrequirementsaccordingtoafrozenplan.厂家根据固定计划完成交货要求的测定标准Units:[Percent%]单位：(%)DataRequired:所需数据：Numberofplannedunits(Numberofplannedunitsfrozenfor5workingdays)计划台数（5个工作日之内的固定计划台数）Numberofincorrectunits(Aunitisincorrectwhenitisnotintime,notincorrectquantity,notincorrectsequenceornotconformingtofrozenplan,differentPNCorproductionline.)生产误差台数（未及时、未按数量要求、未按正确的工序或不符合固定计划、PNC码不相符或生产线不一致的台数）×100%No.ofplannedunits计划生产台数No.ofplannedunits–No.ofincorrectproducedunits计划台数–生产误差台数DSA=8 StockTurnsWip&Supplies在制品&物料存货周转率AmeasureofhowfrequentlytheWIP&SuppliesInventoryisturnedoverinrelationtoannualCostofMaterials.与年度材料成本相关的在制品&物料存货周转频率的测定标准DataRequired:所需数据：12monthrollingperiodCostofMaterials:12个月滚动周期的材料成本12monthrollingaverageofWip&SuppliesInventoryvalue:在制品&物料存货价值的12个月滚动平均数STWS=12monthrollingaveofWip&SuppliesInventoryvalue在制品&物料存货12个月的滚动平均值12monthrollingperiodCostofMaterials12个月滚动周期的材料成本Unit:[frequency]单位：（频率）9 StockTurnsFinishedGoods成品库存周转率AmeasureofhowfrequentlytheFGstockisturnedoverinrelationtotheannualFGsold(STK2).与年度成品销售（STK2）相关的成本库存周转频率的测定标准DataRequired:所需数据：12monthrollingperiodCostofFGsold:12个月滚动周期内销售的成品成本：12monthrollingaverageofFinishedGoodsInventoryvalue:成品库存的12个月滚动平均值：STFG=12monthrollingaveofFGInventoryvalue成品库存的12个月滚动平均值12monthrollingperiodCostofFGsold12个月滚动周期内销售的成品成本Unit:[frequency]单位：（频率）10 ConversionCostPerProduct单台加工成本Afinancialmeasurewhichrelatesthenumberofproductsproducedtothecostofproducingthem.将产品生产数量与其生产成本联系起来的财务测定标准CCPP=TotalquantityofFGunitsproduced生产的成品总量STK1includingvariance–DMincludingvariances包括差异的STK1–包括差异的DMUnit:[€or$/product]单位：（欧元或美元/台）FG=FinishedGoodunit.FG=成品台数DataRequired:所需数据：TotalquantityofFGunitsproduced生产的成品总量STK1includingvariances包括差异的STK1RepresentsthesumofDM,DL,DL-b,ODC,FO-v,includingvariances表示包括差异的直接原材料,直接人工,直接人工福利,ODC,变动制造费用总量11 OverallEquipmentEfficiency设备综合利用率Ameasureofhowefficientlyaprocessisproducingpartswithinthetimeitisplannedtorun对工序流程在计划运转时间内生产零件的效率的测定标准OEE=Availability%×Performance%×Quality%OEE=利用率%×性能%×合格率%Availabilitycompareshowmuchtimetheprocesswasactuallyproducinginrelationtothetimeitwasplannedtorun利用率是实际生产流程时间与计划运行时间的对比Performancecomparesthetheoreticaltimetoprocesstheproducedquantitytotheactualtimetoproducethem性能是生产一定数量产品的理论时间与实际生产时间的对比Qualitycomparesthenumberofpartsthatarerightfirsttmefromtheprocesswithtotalquantityofpartsprocessed合格率是加工一次合格部件数量与部件加工总量的对比DataRequired:所需数据：Rightfirsttimelevelofprocess(100%-NRFT%)加工一次合格率水平（100%-一交不合格率）Totalavailabletime总计利用时间Downtimelosses–plannedandunplanned停机时间损失–计划的和非计划的Actualoperatingtimetakentoproducepartsinperiod周期内生产部件的实际操作时间Numberofpartsproducedinthatperiod该周期内生产的部件数量Idealcycletimeforthepartthroughtheprocess该部件加工的理想周期12 OverallEquipmentEfficiency设备综合利用率___Totalavailabletime总计利用时间Planneddowntime计划停机时间Unplanneddowntime非计划停机时间Totalavailabletime总计利用时间Planneddowntime计划停机时间Availability=利用率x100%Performance=性能IdealcycletimexProcessedquantity理想周期x加工数量Actualoperatingtime实际操作时间x100%Quality=合格率Processedquantity–DefectQuantity加工数量–缺陷数量Processedquantity加工数量x100%13 OverallEquipmentEfficiency设备综合利用率1000625250125Iplantorunamachinefor10hrs,withacycletimeof0.6min/part:PotentialOutput=1000parts.计划让机器运转10小时，周替为每个零件0.6分钟：可能的产量=1000个ButifIlose3hrstobreakdown,2hrstoachangeover.但如果故障停机3个小时，又花了2个小时进行设备转换。Availability=?%Max.PossibleOutput=?parts利用率=?%最大产量可能=?个ButifwehavetorunslowlyduetomachineconditionandbecauseIamanewoperator,Ionlymake250partsinthe5hoursavailable.但是如果由于机器情况不得不让其运转速度放慢，再加上我是个新手，我只能在5个小时内做250个零件。Performance=?%ActualOutput=250parts效能=?%实际产出=250个OEEconceptexample:设备综合利用率案例：14 OverallEquipmentEfficiency设备综合效率Andifhalfofthepartsthatwedomakerequirereworktomakethemintolerance.并且如果我们生产的零件有一半需要按要求返工，以使其在规定公差范围之内Quality=?%GoodPartsProduced=?合格率=?%生产的合格品=?OEE（设备综合利用率）=?%x?%x?%?=?%100062525012515 OEEWorkedExampleOEE实例Amachineoperatesononeshiftofeighthourswith20minutesforbreaks假设一台机器8小时单班，期间会有20分钟计划停机时间.Yesterdaythemachinestoppedfor20minfortooling,20minforbreakdownand20minforadjusting昨天该机器修模停了20分钟，故障20分钟，调试20分钟。Allplannedmaintenanceiscarriedoutoutsidethenormalshifttime(8hours)按计划机器维护安排在正常生产时间以后（8小时以后）Normalplannedoutputis460units.Yesterdaythemachinemade350partsofwhich20werescrappedand30reworked.Machinecycletimeis1minute计划产量为460台。但昨天只生产了350台，其中20台报废，30台返工，设备循环周期为1分钟。WhatistheO.E.E.ofthemachine问该设备的OEE是多少？16 利用率=总可用时间–计划停机时–非计划停机时节x100%总可用时间–计划停机时=480–20–60x100%(480–20)=87%运行率=理论循环时间x加工数量yx100%实际运行时间=1x350x100%400=87.5%=86%合格率=加工数量–缺陷数量x100%加工数量=350–50x100%350O.E.E.=87%x87.5%x86%=65.4%OEEWorkedExampleOEE计算举例17 DisruptionFreePerformance无中断运行AmeasureofProductionEfficiencytomonitordisruptionsinthemanufacturingprocess.制造流程中生产效率对生产中断监测的测定标准DisruptionsaremonitoredbyLostunits中断由损失台数监测Lostunitsarethenumberofunitsthatwerenotproducedduetodisruptionsintheproductionflows,specifiedusingDFPcodesanddefinitionsas:损失台数是指由于生产流程的中断而未能生产的台数，DFP的标准和定义如下：EI–Equipmentissues,MC–Materialcodes,QC–Qualitycontrol,PP–Peopleandprocess,RU–rampupEI–设备问题，MC–材料代码，QC–质量控制，PP–人和工序，RU–持续改善Unit:[%]单位：（%）FG=FinishedGoodunit.FG=成品数量DataRequirements:所需数据：TotalquantityofFGunitsproduced成品生产总台数TheorecticalCapacity理论产能Theoreticalcapacity(100%)理论产能（100%）TotalquantityofFGunitsproduced成品生产总台数DFP=×100%18