CN112287292B - OEE (optical element analysis) improvement and equipment speed loss finding calculation method based on OEE theory - Google Patents
OEE (optical element analysis) improvement and equipment speed loss finding calculation method based on OEE theory Download PDFInfo
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Abstract
The invention relates to model establishment and improvement of production capacity level of factory production equipment, in particular to a method for improving OEE and calculating speed loss of discovery equipment based on OEE theory. The OEE parameter calculation method and device can calculate the OEE parameter of the equipment more accurately; the problem of speed loss of the equipment can be found as soon as possible; the method provides scientific and accurate reference standards for two works of evaluating equipment by production line management staff of manufacturing enterprises and solving the reason behind the yield reduction. The method is not embodied and provided by the traditional OEE calculation method, and when the analysis speed is lost, the value of the traditional OEE is reduced, but the value is slowly reduced, so that the problem of speed loss of equipment cannot be reflected in time, and larger economic loss is inevitably caused, and the method is also intended to be avoided by the invention.
Description
Technical Field
The invention relates to model establishment and improvement of production capacity level of factory production equipment, in particular to a method for improving OEE and calculating speed loss of discovery equipment based on OEE theory.
Background
Typically, each plant in the production process has its maximum capacity in a theoretical sense. However, in actual production, the equipment is stopped due to various factors, such as mechanical failure, cleaning and repairing machine, material delay, product defect, etc., or cannot run with high performance and high standard, or the yield of the produced product is less than one hundred percent. OEE (Overall Equipment Effectiveness) is a separate measuring tool which is used to represent the ratio of actual capacity to theoretical capacity. By analyzing each sub-item of the OEE model, the method accurately and clearly shows how the equipment efficiency is and in which aspect in production faults occur, and is beneficial to the determination of subsequent improvement work.
In actual production, various losses often occur due to deviation of the production condition of industrial equipment from an ideal state, wherein there is a speed loss caused by low-speed operation of the equipment, and finally the production efficiency is reduced, and in order to reduce the economic loss caused by the speed loss as fast as possible, it is urgent to find a method capable of quickly finding out the phenomenon of reducing the production speed of the equipment.
Disclosure of Invention
The invention provides a method for improving OEE and finding equipment speed loss based on an OEE theory, which can obtain more accurate OEE and find equipment speed loss faster, and solves the problems in the prior art.
The technical scheme of the invention is as follows in combination with the accompanying drawings:
a method for calculating OEE improvement and equipment speed loss discovery based on OEE theory, the method comprising the steps of:
step one, an OEE calculation model is established;
collecting and acquiring various parameters in the OEE calculation model;
step three, calculating performance efficiency PE';
step four, OEE for measuring the comprehensive performance of the equipment is calculated 1 ；
Step five, calculating OEE capable of timely finding out speed loss w ；
Step six, obtaining OEE 1 And OEE (optical element) w Counting the report forms;
step seven, by comparing OEE 1 And OEE (optical element) w The trend graph of the equipment is obtained, and the comprehensive efficiency condition and the speed loss condition of the equipment are obtained;
step eight, establishing OEE in the factory according to the step one-step seven 1 And OEE (optical element) w The equipment is managed in a visual mode.
The OEE calculation model is:
OEE = availability time Efficiency (EA) x equipment Performance Efficiency (PE) x qualification Rate (RQ);
the calculating method of the performance efficiency PE' in the third step specifically comprises the following steps:
wherein the theoretical production period of the product is a constant T 0 The actual production period of each product is Ti, and the production period difference is DeltaT i ＝T i -T 0 For n T i There are n sample observations, ΔT 1 ，ΔT 2 ，....ΔT n ；
Find DeltaT 1 、ΔT 2 、...ΔT n The minimum value deltat of (a) (1) And a maximum value DeltaT (n) I.e. DeltaT (1) ＝min(ΔT 1 ，ΔT 2 ，...ΔT n )，ΔT (n) ＝max(ΔT 1 ，ΔT 2 ，...ΔT n ) The method comprises the steps of carrying out a first treatment on the surface of the Selecting less than delta T (1) The sum of the numbers a and a greater than DeltaT (n) Determining the group number k according to the sample capacity, dividing the interval (a, b) into k subintervals, and selecting the division point: a=x 0 ＜x 1 ＜…＜x i-1 ＜x i ＜…＜x k ＝b，
Dividing the interval (a, b) into k subintervals: (a, x) 1 ]，(x 1 ，x 2 ]，...(x i-1 ，x i ]，...，(T k-1 ，b)，
The ith subinterval (x i-1 ，x i ]The length of (2) is: Δx i ＝x i -x i-1 ，i＝1，2，...，k.
Assume that the length of each subinterval is equal:i＝1，2，...，k.
analysis shows that the n data fall within each subinterval (x i-1 ，x i ]Frequency n in i Then calculate the frequencyi=1, 2,; making a histogram; because when the sample size n is large enough, the random variable DeltaT i Falls between the ith cell (T i-1 ，T i ]The frequency within is approximately equal to its probability, namely: f (f) i ≈P{x i-1 ＜X≤T i }，i＝1，2，...，k，
Drawing a histogram by using a large amount of collected data, and obtaining a probability density curve of delta T, wherein the probability density curve is approximately regarded as T and obeys normal distribution; obtaining the expected value and variance of the obtained normal distribution curve by using a moment estimation method; after obtaining a normal curve obtained by fitting and obtaining expected and variance by parameter estimation, taking sample observation values in a range of a section (mu-2 sigma, mu+2 sigma) to average, and removing invalid data generated by ageing problems of equipment or defects of input raw materials from the acquired data; let x=Δt, in the interval (μ -2σ, μ+2σ) there are:
where erf is the error function,is an irrational number, and has the value:
the time average value obtained finally is:where μ is the expectation of the raw data from the moment estimation; thus, the actual production cycle T for calculating PE' is: />T 0 Is a theoretical production period; and then other parameters can be calculated according to the acquired data, so that PE' is obtained.
Step four, OEE for measuring the comprehensive performance of the equipment 1 The calculation method of (a) specifically comprises the following steps:
first, the parameter w is calculated 1 ，w 1 Calculating PE by using PE' obtained in the third step for synthesizing the ratio coefficient of performance 1 ；w 1 The calculation formula of (2) is as follows:wherein Ti is an actual production cycle for producing a product, T 0 Is a theoretical production period; the calculation of PE' is improved, and a calculation formula of a new PE is defined as follows: />
The improved OEE calculation formula is as follows: OEE (optical element) 1 ＝EA×PE 1 XRQ by combining the modified PE, i.e. PE 1 Substitution into OEE 1 The improved OEE is obtained from the calculation formula of (c).
Step four, the OEE capable of timely finding out the speed loss w The calculation method of (a) specifically comprises the following steps:
calculating the parameter w 2 ，w 2 Magnification ratio coefficient, by w 2 Obtaining OEE w The method comprises the steps of carrying out a first treatment on the surface of the Definition of OEE w The calculation formula of (2) is as follows: in order to amplify the ratio coefficient of the light,
OEE w ＝EA×PE 2 ×RQ
wherein,
wherein PE' is obtained in the third step; w (w) 2 Is calculated according to the formula:
wherein n is the number of products, alpha is the percentage of the weighted products in the batch, T i actual And T j actual T for the actual production cycle of a product 0 For the theoretical production cycle, w (T j actual ) As a function of the weight of the material,wherein T is j0 The actual production period counted for the product according to the earlier normal production is a constant in the calculation of the product batch; obviously, with the n products produced most recently, and the variation of their actual production cycle, w (T j actual ) The value of (2) also varies constantly and, because of the explosive growth nature of the exponential function, follows T j actual Will be larger and larger, thus making w 2 Rapidly increasing; will w 2 Substitution into OEE w Obtaining OEE from the calculation formula of (2) w 。
The beneficial effects of the invention are as follows:
1) The OEE parameter calculation method and device can calculate the OEE parameter of the equipment more accurately;
2) The invention can find out the problem of speed loss of the equipment as soon as possible; the method provides scientific and accurate reference standards for two works of evaluating equipment by production line management staff of manufacturing enterprises and solving the reason behind the yield reduction. The method is not embodied and provided by the traditional OEE calculation method, and when the analysis speed is lost, the value of the traditional OEE is reduced, but the value is slowly reduced, so that the problem of speed loss of equipment cannot be reflected in time, and larger economic loss is inevitably caused, and the method is also intended to be avoided by the invention.
Drawings
FIG. 1 is an OEE of a device 1 A time period trend graph;
FIG. 2 is an OEE of a device w A time period trend graph;
FIG. 3 is an OEE of a device 1 And OEE (optical element) w A comparison chart;
fig. 4 is a deltat probability curve distribution diagram.
Detailed Description
A method for calculating OEE improvement and equipment speed loss discovery based on OEE theory, comprising the steps of:
step one, an OEE calculation model is established;
the OEE formula of the current device is:
OEE = availability time Efficiency (EA) x equipment Performance Efficiency (PE) x quality Rate (RQ)
Collecting and acquiring various parameters in the OEE calculation model;
when each parameter in the OEE calculation model is acquired, the original data is collected by using a data warehouse technology, and is read, processed and converted, and then the original data is provided for OEE calculation.
And acquiring various parameters in the OEE calculation model by automatic acquisition. According to the existing advanced data acquisition equipment, various parameters in an OEE calculation model can be obtained. One part of the data, such as planned production time, unplanned production time, total number of produced products and number of qualified products, is extracted from a database of the existing system (such as YMS, MES) of the enterprise, and the other part, mainly equipment state time, is directly grabbed from the equipment system.
Step three, calculating performance efficiency PE';
the calculating method of the performance efficiency PE' in the third step specifically comprises the following steps:
wherein the theoretical production period of the product is a constant T 0 The actual production period of each product is T i The production cycle difference is delta T i ＝T i -T 0 For n T i There are n sample observations, ΔT 1 ，ΔT 2 ，...ΔT n ；
Find DeltaT 1 、ΔT 2 、...ΔT n The minimum value deltat of (a) (1) And a maximum value DeltaT (n) I.e. DeltaT (1) ＝min(ΔT 1 ，ΔT 2 ，...ΔT n )，ΔT (n) ＝max(ΔT 1 ，ΔT 2 ，...ΔT n ) The method comprises the steps of carrying out a first treatment on the surface of the Selecting less than delta T (1) The sum of the numbers a and a greater than DeltaT (n) Determining the group number k according to the sample capacity, dividing the interval (a, b) into k subintervals, and selecting the division point: a=x 0 ＜x 1 ＜…＜x i-1 ＜x i ＜…＜x k ＝b，
Dividing the interval (a, b) into k subintervals: (a, x) 1 ]，(x 1 ，x 2 ]，...(x i - 1 ，x i ]，...，(T k-1 ，b)，
The ith subinterval (x i-1 ，x i ]The length of (2) is: Δx i ＝x i -x i-1 ，i＝1，2，...，k.
Assume that the length of each subinterval is equal:i＝1，2，...，k.
analysis shows that the n data fall within each subinterval (x i-1 ，x i ]Frequency n in i Then calculate the frequencyi=1, 2,; making a histogram; because when the sample size n is large enough, the random variable DeltaT i Falls between the ith cell (T i-1 ，T i ]The frequency within is approximately equal to its probability, namely: f (f) i ≈P{x i-1 ＜X≤T i }，i＝1，2，...，k，
Referring to fig. 4, a histogram is drawn using a large amount of collected data, and a probability density curve of Δt can be obtained, which is approximately regarded as T subject to normal distribution; obtaining the expected value and variance of the obtained normal distribution curve by using a moment estimation method; after obtaining a normal curve obtained by fitting and obtaining expected and variance by parameter estimation, taking sample observation values in a range of a section (mu-2 sigma, mu+2 sigma) to average, and removing invalid data generated by ageing problems of equipment or defects of input raw materials from the acquired data; let x=Δt, in the interval (μ -2σ, μ+2σ) there are:
where erf is the error function,is an irrational number, and has the value:
the time average value obtained finally is:where μ is the expectation of the raw data from the moment estimation; thus, the actual production cycle T for calculating PE' is: />T 0 Is a theoretical production period; and then can calculate according to the acquired dataOther parameters are derived, thus obtaining PE'.
Step four, OEE for measuring the comprehensive performance of the equipment is calculated 1 ；
First, the parameter w is calculated 1 ，w 1 Calculating PE by using PE' obtained in the third step for synthesizing the ratio coefficient of performance 1 ；w 1 The calculation formula of (2) is as follows:wherein T is i T for the actual production cycle of a product 0 Is a theoretical production period; the calculation of PE' is improved, and a calculation formula of a new PE is defined as follows: />
The improved OEE calculation formula is as follows: OEE (optical element) 1 ＝EA×PE 1 XRQ by combining the modified PE, i.e. PE 1 Substitution into OEE 1 The improved OEE is obtained from the calculation formula of (c).
Step five, calculating OEE capable of timely finding out speed loss w ；
Calculating the parameter w 2 ，w 2 Magnification ratio coefficient, by w 2 Obtaining OEE w The method comprises the steps of carrying out a first treatment on the surface of the Definition of OEE w The calculation formula of (2) is as follows:
OEE w ＝EA×PE 2 ×RQ
wherein,
wherein PE' is obtained in the third step; w (w) 2 Is calculated according to the formula:
wherein n is the number of products, the alpha weighted products are the percentage of the batch of products, T i actual And T j actual T for the actual production cycle of a product 0 For the theoretical production cycle, w (T j actual ) As a function of the weight of the material,wherein T is j0 The actual production period counted for the product according to the earlier normal production is a constant in the calculation of the product batch; obviously, with the n products produced most recently, and the variation of their actual production cycle, w (T j actual ) The value of (2) also varies constantly and, because of the explosive growth nature of the exponential function, follows T j actual Will be larger and larger, thus making w 2 Rapidly increasing; will w 2 Substitution into OEE w Obtaining OEE from the calculation formula of (2) w It can be obtained that when the equipment is operated at low speed, w as the actual production period of the product becomes longer 2 The value of (2) can be changed rapidly, and when the speed loss of the equipment is increased, the weight of the equipment can be increased rapidly so as to enable OEE w Can be changed rapidly. Thus, by observing OEE w We can find the speed loss of the production equipment faster.
Step six, obtaining OEE 1 And OEE (optical element) w Counting the report forms;
the summary table is calculated from the data obtained from the collected data at the following time:
TABLE 1 OEE 1 Time-interval dependent data statistics
TABLE 2 OEE w Time-interval dependent data statistics
TABLE 3 OEE 1 And OEE (optical element) w Time-sliced data comparison
Seventh, according to the above steps, the OEE of a certain device can be obtained 1 Time period trend graph and OEE w Time period trend graph we can see the OEE of this device through FIG. 1 1 Trend graph, this OEE trend graph can reflect the comprehensive efficiency of equipment more. By observing OEE w Trend graph (fig. 2), we can see the equipment OEE w Rapidly decreasing and eventually decreasing in value more rapidly as the velocity loss increases. Referring to FIG. 3, by and OEE w Comparison of trend graphs shows that OEE can be found obviously w The low-efficiency production condition of the equipment can be reflected rapidly.
Step eight, according to the above steps, applying the improved OEE in actual production 1 And OEE (optical element) w Through the visual mode, the comprehensive efficiency change condition of the equipment can be more accurately seen, and whether the equipment is running at a low speed can be rapidly found, so that convenience is provided for plant managers and plant maintainers, and efficient production of a plant is facilitated.
Claims (2)
1. A method for calculating OEE improvement and equipment speed loss discovery based on OEE theory, comprising the steps of:
step one, an OEE calculation model is established;
collecting and acquiring various parameters in the OEE calculation model;
step three, calculating performance efficiency PE';
step four, OEE for measuring the comprehensive performance of the equipment is calculated 1 ；
Step five, calculating OEE capable of timely finding out speed loss w ；
Step six, obtaining OEE 1 And OEE (optical element) w Counting the report forms;
step seven, by comparing OEE 1 And OEE (optical element) w The trend graph of the equipment is obtained, and the comprehensive efficiency condition and the speed loss condition of the equipment are obtained;
step eight, establishing OEE in the factory according to the step one to the step seven 1 And OEE (optical element) w The equipment is managed in a visual mode;
the calculating method of the performance efficiency PE' in the third step specifically comprises the following steps:
wherein the theoretical production period of the product is a constant T 0 The actual production period of each product is T i The production cycle difference is delta T i ＝T i- T 0 For n T i There are n sample observations, ΔT 1 ,ΔT 2 ,…ΔT n ；
Find DeltaT 1 、ΔT 2 、…ΔT n The minimum value deltat of (a) (1) And a maximum value DeltaT (n) I.e. DeltaT (1) ＝min(ΔT 1 ,ΔT 2 ,…ΔT n ),ΔT (n) ＝max(ΔT 1 ,ΔT 2 ,…ΔT n ) The method comprises the steps of carrying out a first treatment on the surface of the Selecting less than delta T (1) The sum of the numbers a and a greater than DeltaT (n) Determining the group number k according to the sample capacity, dividing the interval (a, b) into k subintervals, and selecting the division point: a=x 0 <x 1 <…<x i-1 <x i <…<x k ＝b，
Dividing the interval (a, b) into k subintervals: (a, x) 1 ],(x 1 ,x 2 ],…(x i-1 ,x i ],…,(T k-1 ,b),
The ith subinterval (x i-1 ,x i ]The length of (2) is: Δx i ＝x i -x i-1 ,i＝1,2,…,k；
Assume that the length of each subinterval is equal:i＝1,2,…,k；
analysis shows that the n data fall within each subinterval (x i-1 ,x i ]Frequency n in i Then calculate the frequencyi=1, 2, …, k; making a histogram;
drawing a histogram by using a large amount of collected data to obtain a probability density curve of delta T, and regarding the probability density curve as T to be subjected to normal distribution; obtaining the expected value and variance of the obtained normal distribution curve by using a moment estimation method; after obtaining a normal curve obtained by fitting and obtaining expected and variance by parameter estimation, taking sample observation values in a range of a section (mu-2sigma, mu+2sigma) to calculate an average value, and removing invalid data generated by ageing problems of equipment or defects of input raw materials from the acquired data; let x=Δt, in the interval (μ -2σ, μ+2σ) there are:
where erf is the error function,is an irrational number, and has the value:
the time average value obtained finally is:where μ is the expectation of the raw data from the moment estimation; thus, the actual production cycle T for calculating PE' is: />T 0 Is a theoretical production period; then calculating other parameters according to the acquired data, thus obtaining PE';
step four, OEE for measuring the comprehensive performance of the equipment 1 The calculating method of (a) hasThe body is as follows:
first, the parameter w is calculated 1 ，w 1 Calculating PE by using PE' obtained in the third step for synthesizing the ratio coefficient of performance 1 ；w 1 The calculation formula of (2) is as follows:the calculation of PE' is improved, and a calculation formula of a new PE is defined as follows: />
The improved OEE calculation formula is as follows: OEE (optical element) 1 ＝EA×PE 1 XRQ by combining the modified PE, i.e. PE 1 Substitution into OEE 1 Obtaining improved OEE according to the calculation formula of (2);
step four, the OEE capable of timely finding out the speed loss w The calculation method of (a) specifically comprises the following steps:
calculating the parameter w 2 ，w 2 Magnification ratio coefficient, by w 2 Obtaining OEE w The method comprises the steps of carrying out a first treatment on the surface of the Definition of OEE w The calculation formula of (2) is as follows: in order to amplify the ratio coefficient of the light,
OEE w ＝EA×PE 2 ×RQ
wherein,EA is available time efficiency; RQ is the qualified rate;
wherein PE' is obtained in the third step; w (w) 2 Is calculated according to the formula:
wherein n is the number of products, alpha is the percentage of the weighted products in the batch, T i actual And T j actual To produce an actual production cycle of a product, w (T j actual ) As a function of the weight of the material,wherein T is j0 The actual production period counted for the product according to the earlier normal production is a constant in the calculation of the product batch; obviously, with the n products produced most recently, and the variation of their actual production cycle, w (T j actual ) The value of (2) also varies constantly and, because of the explosive growth nature of the exponential function, follows T j actual Will be larger and larger, thus making w 2 Rapidly increasing; will w 2 Substitution into OEE w Obtaining OEE from the calculation formula of (2) w 。
2. The method for calculating the OEE improvement and discovery device speed loss based on the OEE theory of claim 1, wherein the OEE calculation model in step one is:
OEE = availability time efficiency EA x device performance efficiency PE x quality rate RQ;
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