Thư viện
KPIs phòng bảo trì
Bảo trì có kế hoạch PM Planned Maintenance là một nội dung của bảo trì năng suất toàn diện TPM. Bảo trì có kế hoạch Planned Maintenance PM triển khai cho phòng bảo trì của công ty.
Một số chỉ số đo đạc hiệu quả bảo trì có kế hoạch Planned Maintenance PM khi áp dụng chương trình bảo trì năng suất toàn diện TPM
- Độ tin cậy & Khả năng duy trì
- Số hư hỏng xảy ra (# Breakdowns)
- MTBF
- MTTR
- % OEE mất do hư hỏng (% OEE due to breakdowns)
- Hiệu quả bảo trì
- % OEE mất do bảo trì có kế hoạch PM (% OEE loss due to planned maintenance)
- Số ngày dừng máy để bảo trì có kế hoạch (Shutdown maintenance days)
- % công việc được lập KH & % hoàn thành kế hoạch bảo trì (% planned vs. completed)
- Chi phí bảo trì
- Tổng chi phí bảo trì (Overall maintenance costs)
- Chi phí phụ tùng thay thế (Spare part costs)
- Chi phí phụ tùng tồn kho (Spare part inventory)
- Chi phí thuê nhà thầu (Contractor costs)
- Chi phí lao động (Labor costs)
- Các mục tiêu khác
- Tỉ lệ loại trừ hư hỏng (Breakdown elimination rate)
- Kỹ năng nhân viên (Technical skill profile).
Bảo trì có kế hoạch PM - Maintenance Indicators: Reliability and Maintainability
|
Indicator |
Formula |
Target |
Interval |
Remarks |
|
Breakdown Frequency |
Total # of stops due to Breakdown X 100 Scheduled Run Time |
0.10% or less |
Monthly |
Count stoppages lasting 10 or more minutes |
|
Breakdown Severity Rate |
Total stoppage time due to breakdown X 100 Scheduled Run Time |
.15% or less |
Monthly |
Hold total stoppage time to within 1hr/month |
|
Emergency Maintenance Rate |
_______Number of EM jobs X 100_______ TBM jobs + CBM jobs + BD jobs + EM jobs |
.5% or less |
Monthly |
TBM = Time Based Maint CBM = Conditioned Based Maint BD = Breakdown Maint EM = Emergency Maint |
|
Cost of stoppages due to breakdowns |
Stoppage time X cost per unit time |
Minimize |
Monthly |
Include lost production, energy costs, and labor hour losses |
|
Number of idlings and minor stops |
Trend in number of idlings and minor stops |
0 |
Monthly total (daily average) |
Count number of idlings and minor stops lasting under 10 minutes |
|
MTBF |
______Total operating time (uptime)______ Minor stops + Breakdowns + Process Failures |
2-10 times |
Monthly |
Average failure interval |
|
MTBBD |
Total operating time (uptime) Number of Breakdowns |
1-10 times |
Monthly |
Average failure interval |
|
MTTR |
Sum of repair job times Number of repair jobs |
50% -80% reduction |
Monthly |
Mean Time To Repair |
Bảo trì có kế hoạch PM - Maintenance Indicators: Reliability and Maintainability
|
Indicator |
Formula |
Target |
Interval |
Remarks |
|
Planned Maintenance impact to PR |
Down Time due to Planned Maintenance Scheduled Run Time |
<5% |
Monthly |
the goal is to extend intervals , reduce MTTR, convert downtime tasks to uptime tasks |
|
Shutdown Maintenance Days reduction (SMD) |
Previous SMD Present SMD |
In accord with annual targets |
Annually |
The goal is to extend the numbers of days of continuous production |
|
Vertical startup after shutdown maintenance |
Trend in number of startup problems after shutdown maintenance |
Minimize |
Annually |
Prevent early failures after shutdown maintenance |
|
Planned Maintenance achievement rate |
___Number of PM jobs completed___ Number of jobs planned & scheduled |
90% or above |
Monthly |
Indicates level of planning & scheduling of maintenance |
|
Corrective Maintenance trend (CM) |
Trend in CM (improvements) implemented |
At least 10 per PM resource/yr |
Monthly |
Level of Corrective Maintenance (CM) indicates technical ability of PM resources |
|
Maintenance effort hour reduction trend |
Trend in reduction of total maintenance hours required |
In accord with annual targets |
Monthly |
|
|
Inventory Record Accuracy (IRA) |
# Accurate book inventory records X 100 # Book inventory records audited |
98% |
Monthly |
See table 7b |
|
Bill of material (BOM) accuracy |
Number of accurate Bills of Materials X 100 Number of Bills of Materials Audited |
98% |
Monthly |
See table 7c |
|
Planned Maintenance |
Jobs planned, scheduled 1 month in advance, __& completed in month being measured__ All jobs completed in mo. being measured |
95% |
Monthly |
See table 7d |
|
Parts Availability |
[(Total transactions by line item) - ___(Line items out of stock)] X 100___ Total transactions by line item |
100% |
Monthly |
See table 7d |
Bảo trì có kế hoạch PM - Maintenance Indicators: Reliability and Maintainability
|
Indicator |
Formula |
Target |
Interval |
Remarks |
|
Overall maintenance cost rate |
Total maintenance cost X 100 Total production cost |
In accord with annual targets |
Monthly |
Indicates the proportion of total costs spent on maintenance |
|
Unit maintenance costs |
Maintenance cost X 100 Production Volume |
20% reduction |
Monthly |
Maintenance cost per product unit |
|
Maintenance cost reduction rate |
Trend in maintenance cost reduction |
20% reduction |
Monthly |
Compared to costs at kick off. |
|
Breakdown repair costs |
Trend in cost of breakdown repairs |
In accord with annual targets |
Monthly |
Compared to costs at kick off. |
|
Contractor costs |
Trend of contractor spending |
In accord with annual targets |
Monthly |
Compared to costs at kick off. |
|
Reduction in spare inventories |
Trend of spare part inventory value |
In accord with annual targets |
Monthly |
Indication of increasing component life and planning & scheduling efforts |
|
Maintenance cost rate |
(Maintenance cost) + (Stoppage Loss) X 100 Total Production Cost |
In accord with annual targets |
Monthly |
Compared to costs at kick off. |
Bảo trì có kế hoạch PM - Maintenance Indicators: Reliability and Maintainability
|
Indicator |
Formula |
Target |
Interval |
Remarks |
|
Contract maintenance rate (1) |
Extent due to lack of technology and skills |
In accord with annual targets |
Annually |
Compared to costs at kick off. |
|
Contract maintenance rate (2) |
Extent needed to absorb capacity (labor) shortages |
In accord with annual targets |
Annually |
Compared to costs at kick off. |
|
Renovation rate |
Proportion of obsolete equipment units updated |
In accord with annual targets |
Annually |
Modernized outdated equipment |
|
In-house development |
Trend in number of items of equipment developed in-house |
In accord with annual targets |
Annually |
Include remodeled items |
|
Breakdown Elimination rate |
(Failure Analysis rate) X (Countermeasure implementation rate) X (Recurrence prevention rate) |
90% |
Monthly |
To highlight weaknesses in failure countermeasures and unsure organization continues to eliminate breakdowns |
Recommended Initial Measurement Items for Effect and Target Setting
|
No. |
Measuring Items |
Calculation |
Target |
|
1 |
Equipment breakdown occurrences |
Actual number of occurrences per each failure classification (Major, moderate, minor |
Major/moderate breakdown = 0 Minor breakdown = 1/10 |
|
2 |
Equipment breakdown rate |
Total downtime due to breakdown X 100 Total operating hours (uptime) |
Less than .15% |
|
3 |
Equipment breakdown frequency rate |
Total breakdown occurrences X 100 Total operating hours (uptime) |
Less than .10% |
|
4 |
Maintenance cost as material input |
__Maintenance cost__ Production throughput |
20% reduction |
|
5 |
Reduction in spare inventories |
Trend of spare part inventory value |
30% to 50% reduction |
|
6 |
PM completion rate |
_____Number of PM work done X 100_____ Number of PM work planned & scheduled |
More than 90% |
|
7 |
Preventive Maintenance rate |
(TBM + CBM + BM + CM) + 100 TBM + CBM + BM + CM + EM |
More than 90% |
|
8 |
Maintenance Improvement Rate |
(# of maintenance improvements) X 100 Total number of maintenance jobs |
More than 10 improvements/person/year |
|
9 |
MTBBD |
Total operating time (uptime) Total number of breakdowns |
2-10 times |
|
10 |
# of Focused Improvements for Equipment |
# of themes registered |
Meet annual target |
INVENTORY RECORD ACCURACY (IRA) - MATERIALS & FINISHED PRODUCT
DEFINITION:
a. The inventory record accuracy is based upon cycle counts versus book inventory records.
b. The inventory record accuracy is the percent of accurate book inventory records versus total book inventory records audited.
c. The book inventory record is accurate if the information is complete and correct with respect to location, item number, quantity, status (if appropriate), and control number (if appropriate).
d. A tolerance may be used for the quantity. The quantity tolerance for materials is 3% maximum. The quantity tolerance for finished product is 0%.
e. The inventory record accuracy is measured after the cycle count and after the book inventory and the physical inventory are reconciled.
f. The inventory record accuracy is calculated on a daily basis. The daily results are used to calculate the monthly results.
g. The inventory record accuracy is reported on a quarterly basis.
h. All inventory records are audited a minimum of once per year.
i. The target performance for materials is 95% minimum. The target performance for finished product is 98% minimum.
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Ông: Nguyễn Đình Cương.
Chuyên viên Tư vấn Lean - TPM, công ty Tư vấn TST VN.
Tin cùng chủ đề
Huấn luyện sản xuất tinh gọn (LEAN) tại cơ sở của khách hàng. Loss Elimination Sự khác nhau giữa bảo trì có kế hoạch PM so với bảo trì truyền thống Tư duy các khái niệm mới về Total Productive Maintenance - TPM 5S implementation process 7 bước triển khai bảo trì tự quản AM OEE - Overall Equipment Effectiveness Tổng quan Bảo trì tự quản AM bước 4 Hướng dẫn đánh giá AM bước 2 Hướng dẫn đánh giá AM bước 1
