将军集团设备管理金字塔(1)

建立管理的金字塔ESHTABLISHMENTOFMANAGEMENTPYRAMID陈毅力ChenYili将军集团设备管理模式TheEquipmentManagementModeofGeneralTobaccoGroup’s设备管理究竟追求什么？Whatdoesmaintenancepursue?最大程度最大程度的不是供的利用设备发挥设备效率人观赏HowtousetheHowtobringthe的花瓶equipmenttofunctionofthethegreatestextent?equipmentintothefullplay?设备的理想利用状态TheIdealUsageofEquipment假设存在两个百分之百ASSUMEEXISTINGTWOONEHUNDREDPERCENT设备最长设备无停ThelongestFullefficient日历工作机全效calendarworkingoperatingwithout时间100%100%运行timebreakdown追求设备时间利用率和有效作业率的乘积SEEKFORTHEPRODUCTOFUTILIZATIONANDOVERALLEFFICIENTCYOFEQUIPMENT设备综合效率指数=设备生产时间利用率X设备有效作业率ComprehensiveEquipmentEfficiencyIndex=ProductionTimeUtilizationXOverallEfficiency设备生产时间利用率=设备有效作业率=设备生产时间/日历时间实际产量/理论产量ProductionTimeUtilization=OverallEfficiency=ProductionTime/CalendarTimeActualOutput/TheoreticalOutput如何提高设备综合效率指数HOWTOINCREASETHEOVERALLEFFICIENCYINDEXOFEQUIPMENTHowtoincreaseHowtoincreasetheutilization?theefficiency?提高时间利用率提高有效作业率生产组织方式设备管理模式ThetypeofproductionThetypeofmaintenanceorganizationmanagementDIFFERENTTIMEUTILIZATIONGIVESDIFFERENTDIFFERENTTYPEOFPRODUCTIONORGANIZATION不同生产组织方式得到不同设备生产时间利用率生产方式全年工作每天生产全年生产折合日历生产时production天数时数时数天数间利用率organizationtotaldaysworkinghrsworkinghrscalendarTimetypeinayearperdayperyeardaysUtilization单班运行2548203284.6723.2%1shift二班生产254164064169.3046.4%2shifts三班生产254205080211.6760.0%3shifts四班三转355207100295.8381.1%4shiftsTIMEUTILIZATIONINDIFFERENTTYPESOFORGANIZATION不同组织形式对时间利用率的影响0.00%10.00%20.00%30.00%40.00%50.00%60.00%70.00%80.00%90.00%生产时间利用率TIMEUTILIZATION单班生产1shift二班生产2shifts三班生产3shifts四班三转4shiftsin3turns四班三运转还有优点THEOTHERADVANTAGESOF4SHIFTSIN3TURNS加速设备折旧SpeeduptheEquipmentDepreciation用电消峰填谷BalancetheElectricityConsumption锅炉均衡运行BoilerinaSmoothlyRunning不同有效作业率与不同生产组织方式的关系DIFFERENTOEEANDPATERNOFORANIZATION以PROTOS7000支/分计算，理论年产量为国为73584箱生产方式生产时间设备有效设备综合年产量production利用率作业率效率指数（箱）organizationTimeOEEComprehensiveyearlyoutputtypeUtilizationEfficiencyIndex(case)单班运行23.2%100%0.232170711shift二班生产46.4%100%0.464341432shifts三班生产60.0%90%0.540397353shifts四班三转81.7%80%0.654481244shifts在有效作业率下降的情况下，随着生产组织形式的调整，设备综合效率指数仍然上升。Theefficiencyindexisincreasingalongwiththealternationofproductionorganizationtype.00.10.20.30.40.50.60.70.80.91有效作业率OEE综合效率指数EFFICIENCYINDEX年产量单班运转1SHIFT二班运转2SHIFTS三班运转3SHIFTS四班三转4SHIFTSIN3如何提高设备有效作业率？Howtoincreasetheoverallequipmentefficiency?我们从以下三个方面着手。Wetakefollowing3measures.提高有效作业率的三块基石The3foundationstonestoincreasetheoverallequipmentefficiency设备有效作业率OEE设备基础保养维修模式原料对设备的适应性BASICMAINTENANCESUITABILTYOFMAINTENANCEMODEMATERILS设备管理的基石之一基础保养ONEOFTHEMANAGEMENTFOUNDATIONBASICMAINTENANCE三加一模式：三个清洁，加一个润滑THEMODEOF3PLUS1：3CLEANINGANDALUBRICATION+设备清洁大有文章可做MANYIMPLICATIONSINSIDECLEANING第一是清洁，第二是清洁，第三还是清洁CLEANING，CLEANING，ANDCLEANINGAGAIN清洁意识-清洁时间-清洁得法CLEANINGIDEOLOGYCLEANINGTIMECLEANINGMETHODOLOGY清洁就是维修CLEANINGISMAINTENANCE设备管理的基石之二维修模式设备终生不大修THESECONDFOUNDATIONOFEQUIPMENTMANAGEMENTMAINTENANCEMODEGENERALOVERHAULFREEINTHEWHOLESERVICELIFEOFEQUIPMENT济南卷烟厂终生不大修实践THEPRACTICEOFOVERHAULFREEMAINTENANCEINJINANCIGARETTEFACTORY怎么修？HOWTOREPAIR？过去：二年一大修，一年一中修，半年一小修；PAST：ANOVERHAULEVERYTWO-YEAR，AMIDDLESIZEDMAINTENANCEEVERYYEAR,AMINORMAINTENANCEEVERYHALF-YEAR；现在：项修，总成维修，组件维修，目标：保证设备终生不大修。NOW：ITEMMAINTENANCE，“ASSEMBLY”，ORCOMPONENTMAINTENANCETOENSURE“OVERHAULFREEMAINTENANCE”设备终生不大修取得的效益THEEFFICIENCYOFOVERHAULFREEPOLICY比较表COMPARISON设备维修方式一次费用12年总次数总费用EQUIPMENTMODECOST/MTIMESIN12YTOTALCOSTMK—95大修160万元6960万元OVERHAUL1.6MILLION9.6MILLIONMK—95项修12万元24288万元ITEMMAINT.0.12MILLION2.88MILLION费用节省672万元COSTSAVING6.72MILLION设备管理的基石之三原辅料对设备的适应性THETHIRDMANAGEMENTFOUNDATIONSUITABILITYOFRAWMATERIALTOTHEEQUIPMENT“3A”备件管理3AOrientedSparePartManagement设备-部件-零件均做A，B,C分类，得到27个类；Equipment,assemblyandpartareallclassifiedintoA,B,C,then27differentclassesaregained.划分四个重要性等级，采用不同关键性级别管理；Fourimportancegradesareclassifiedandmanagedindifferentway.再按照零件消耗规律，构造出9个模型。Accordingtherulesofsparepartconsumption,9modelsarestructured.AAA，AAB，AAC，ABA，ACA，ABB，ABC，ACB,ACC，BAA，BAB，BAC，BBA，BCA，BBB，BCB，BBC，BCC，CAA，CAB，CBA，CBB，CAC，CCA，CBC，CCB，CCCModelsof3Asparepartsmanagement3A备件管理模型最关键重要一般其他KEYIMPORTANTGENERALOTHER常规消耗件冗余常规模型一般消耗模型可短缺消耗模型零REGULARREGULARREDUNDANTCOMMONDIFICIENTABLEZERO短时独立需求冗余独立模型一般独立模型可短缺独立模型库PERIODNEEDEDPERIODREDUNDANTCOMMONPERIODDIFICIENTABLEZERO缺乏相关信息冗余上下限模型一般上下限模型可短缺独立模型存INFO.DEFICIENTREDUNDANTLIMITEDCOMMONLIMITEDDIFICIENTABLEZERO零库存零库存零库存零库存ZEROZEROZEROZERO维修是生产力MAINTENANCEISPRODUCTIVITY两大管理理念-全员，规范TwoGreatManagementIdeas--AllMembersParticipating&Normalization1全员化Full-staff2规范化Normalization将军集团综合一体化目标TargetIntegration:90-38-1190：设备有效作业率达到90%以上；OverallEquipmentEfficiencyisabove90%38：单箱卷烟消耗烟叶在38公斤以下；Thetobaccoconsumptionpercaseofcigaretteisbelow38kg.11：实现1机1人，1线1人操作。Eachproductionmachine(orlinesection)isoperatedbyonlyoneoperator.管理的连锁保证体系THEFOURCHAINASSURANCESYSTEMSOFMANGEMENT培训工作设备工艺产品以培训质量保证工作质量以“教人以会”为宗旨，保证培训质量；授之以鱼，未若授之以渔Itisbettertoteachfishingthantogivefish.以工作质量保证设备质量Toassureequipmentqualitywithworkquality以设备质量保证工艺质量Toassureprocessqualitywithequipmentquality.以工艺质量保证产品质量Toassureproductqualitywithprocessquality.设备管理金字塔结构一个目标提高劳onegoal动生产率百万箱千人