IE,Q&PC,REL kpis.docx

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1、INDUSTRIA1.EFFICIENCYOEE-FIoat1.ine21. Definition22. Explanation23. 1.ossdistribution2PRoDUCTiVITY-FIoatline21. Definition22. Explanation3MANUFACTURINGCOST31. Definition32. Explanation3ENERGYCONSUMPTION31. Definition32. Explanation4OEE-Transformationlines81. Definition82. Furtherexplanation&lossesdi

2、stribution8PRoDuCTiVITY-Transformation1.ines111. Definition112. Explanation11QUA1.ITYANDPROCESSCONTRO1.12C1.AIMS121. Definition122. Explanation123. Distributionbytype12Dedomagement131. Definition132. Explanation133. Distributionbytype14RE1.IABI1.ITY15INTRODUCTION15MAINTENANCECOSTS(4kpis)161. TotalMa

3、intenance162. FloatFactorymaintenanceCost163. MaintenanceDept.Cost164. Divisionbytypeofmaintenance16PERFORMANCE(4Kpis)171. (NPl)Breakdownswithproductionloss172. (NP3)Breakdownswithandwithoutproductionloss173. (TRP)PreventivePlannedmaintenancecompletion4. (PIM)1.ossesofProductionformaintenanceINDUSTR

4、IA1.EFFlaENCYOEE-Float1.ine1. DefinitionGoodProduction(tons)OEE,=Theoretical1.inePull(tons)2. Explanation GoodProduction:goodglassstackedandreadytobesenttothecustomer Theoretical1.inePull:thesmallerbetweenTheoreticalFurnacePull(tons)andTheoreticalFloatPull(tons)oTheoreticalFurnacePull: IfCullet2()%S

5、GCVNominallDefinitionUifCuliet20%SGCVNominUlPuHI-(realculletnue-2O%)2oTheoFloatPull=Max1.ehrSpeedThicknessXPXNetWidth(1+Trim.obj) Thickness：Nominalproductionthickness Netwidth:GlasswidthafteredgetrimmingoTrimmingobjective：TrimminglossobjectivedefinedbyDTIforeachthicknessoMax1.ehrspeed:Maximum1.ehrsp

6、eedachievablebythelineoGlassdensity=2,515gcmj3.1.ossdistribution100%OEEAva4abilitCOSMCf.c55.i35MCCEparametersalreadyavailablenIRISNote:YieldanditsrelatedlossesisamandatoryKPIthatisreviewedmonthlyintheGSPRODUCTMTY-Floatliner,.Goodproduction(tonnes)Productivity=：2. Explanation GOodproduction(tons)=goo

7、dglass(intonnes)stackedandreadytobesenttotheclient MH=(HoursxHeadcount)Overtime-Traininghours Headcount=Float+Warehouse+FGUFCA FGU=CostControlling+PlantDirector+HR+Purchasing+WCM FCA=Engineering+ProductionPlanning+Quality Hours:numberofhoursworkedduringtheconsideredperiodMANUFACTURINGCOST1. Definiti

8、onManufacturingCost=R25+R31Glosspurchases2. ExplanationR25:StandardcostR31:Manufacturingandpurchasingvariancesvariancesonstandardcost)Glasspurchases：costofglassboughtfromotherSGGfactoriesENERGYCONSUMPTION1. DefinitionTheenergyKPIisdefinedasadelta(%)betweentherealspecificenergyconsumptionandthetheore

9、ticalspecificenergyconsumptionforagivenperiod:Deltatotheo(%)=TheoreticalThisKPIisfollowedonamonthvbasisforallfactoriesandreviewedintheG5aspartoftheenergyconsumptionreductionproject.Anoteaboutthemeasurementsystem:AllinformationneededtocalculateandfollowthisKPIisfoundintheIRISsystem,includingallthecoe

10、fficientsofthetheoreticalcalculationasdefinedbySGCV.AllrealconsumptiondatashouldbetakenfromtheDCSsystemasanaccumulatedvaluefor24hours.No“spotmeasurementsshouldbeusedunderanycircumstance.GasconsumptiondatashouldexcludetheconsumptionforheatinguptheFeedersandthegasusedforthethermalpurgeofregenerators,a

11、lsoanygasconsumptionintheFloatbathexitendand1.ehrshouldbeexcluded.Allotherconsumptionshouldbeincluded.2. ExplanationCalculationofthemonthlyrealspecificconsumption(Real)Themonthlytotalrealspecificconsumptioniscalculatedusingthedailyconsumptionofthethreeenergysourcesinthefurnace:gas,fueloilandelectric

12、alboosting.SteP1：CalCUIatetherealSDeCifiCCOnSUmPtiOnforgasForgas,thedailyconsumptioniscalculatedusingthereadingsfromthegasflowmeterassociatedtothefurnace(includingthegasflowtotheworkingendburners).Thetotalmeasuredgasflowfortheday(inNm3)isthenconvertedintoitsenergyequivalentusingthegas,NHV(NetHeating

13、Value,inkcalNm3).Finally,thisenergyvalue(inkcalisdividedbytheequivalentpullat20%cullet(inkg)fortheday,resultingintherealgosspecificconsumption(inkcal/kg):rEqttivaleiitPuUSteP2:CalCUlatetherealSPeCifiCconsumptionforfuelOilForfuel,thedailyconsumptioniscalculatedusingthereadingsfromthefueloilflowmetera

14、ssociatedtothefurnace.Thetotalmeasuredflowfortheday(inkg)isthenconvertedintoitsenergyequivalentusingthefueloilsNHV(NetHeatingValue,inkcal/kg).Finally,thisenergyvalue(inkcalisdividedbytheequivalentpullat20%cullet(inkg)fortheday,resultingintherealfuelspecificconsumption(inkcal/kg):也32EquivalentPullSte

15、P3:CaICuIatetherealSPeCifiCCOnSUmPtiOnforelectricalboostin以Fortheelectricalboostingitissomewhatsimpler,sincethe“electricalflow“totheelectrodesisalreadygiveninkilowatts.Thetotalamountofelectricalflowduringtheday(inkWh)isconvertedintokcalusingtherelationship1kWh=860kcal.Finally,thisenergyvalue(inkcal)

16、isdividedbytheequivalentpullat20%culletikg)fortheday,resultingintherealelectricalspecificconsumption(inkcal/kg)：_fEieciricaIFiowkWlt)860Keti1.lfcniri.=e*EiiuivalentPuIlSteP4：CaICUIatethetotalrealSPeCifiCConSUmPtiOnOncethedailyspecificconsumptionsfromthethreeenergysourcesarecalculated,wedefinetheirsu

17、masthetotalrealspecificconsumptionfortheday:ReaKday)=Rea1.+Realllirl+Realrtr(lnif/Tocalculatethetotalrealspecificconsumptionoveraperiod(inthiscasetheentiremonth),wecalculatetheweightedaverageoftherealspecificconsumptionforeachdayusingthedailyequivalentpullat20%culletastheweighingfactor：EEquivaIenPuI

18、Kday)t-Real(day)lReaKmonth)=-Uytquvalentiull(day)tiCMnlThiscorrespondstotheRealtermintheKPIequation.Calculationofthemonthlytheoreticalspecificconsumption(Theoretical)Themonthlytheoreticalspecificconsumptioniscalculatedusingthedailytheoreticalformulaprovidedbythefurnacemanufacturer(SGCV).SteP1:CalCUI

19、atethedailytotaltheoreticalConSIJmPtionWedefinethetotaldailytheoreticalenergyconsumptionCTotaIinkcal)as:CTotaI=NH/a,.,j(A+D(T-E)+BT(-C%Cullet)Where:oT:istherealfurnacepullratefortheday,givenintonnesperdayoNHVtneo：isthetheoreticalNHVforthemainenergysource(gasorfueloil)usedinthefurnace.Itisgiveneither

20、inkcalNm3forgas,orkcal/kgforfueloil.o%Cullet:isculletratefortheday,betweenOand1oA,B,Cand,D:areconstantsthatdependonthefurnacedesign,givenbySGCVTheNHVttwusedintheformulashouldalwaysbethetheoreticalNHVusedbySGCVtodeterminetheA,B,CandDconstants.Step2:CaICUlatethedailySPeCifiCtheoreticalConSlJmPtionat20

21、%culletThespecifictheoreticalconsumption(inkcal/kg)isobtainedusingtheequivalentpullrate(inkg)at20%cullet:Step3:COrreCtforthedifferencebetweenRaSandfueloilformulasForseveralreasons,gasandfueloildonothavethesameefficiencyregardingthefurnaceconsumption(heattransfer,quantityoffumes,etc).Simplifiedapproa

22、chshowsthatgasis3.8%lessefficientthanfueloil.Asaconsequence,youneed3.8%moregasinyourfurnacethanasamefurnaceusingfueloil(allotherfactorsbeingconstant).Thisdifferenceistakenintoaccountinthetheoreticalcalculationofthespecificconsumption.oFurnacesusingtheGasformula:thefurnaceusesaGasformula,butthecombus

23、tionismadepartiallyorcompletelywithfuel.The3.8%correctionmustbeappliedonlytothefuelpart:Tlieomil=Theo3(%FuelX(I-0.038)+%(ms)oFurnacesusingtheFUelOilformula:thefurnaceusesaFueloilformula,butthecombustionismadepartiallyorcompletelywithgas.The3.8%correctionmustbeappliedonlytothegaspart:Tlieomil=Theofxr

24、t(%Fuel+%Ga.vx(l+0.038)Where%Feland%Gascorrespondtothepercentageofeachofthetwoenergysourcesintherealdailyconsumption.Step4：AdjustthetheoreticalconsumptionforthefurnaceaeAsthefurnaceaginghasanimpactontheenergyconsumption,weapplyanagingfactorthatdependsonthefurnaceslifetime.Thisadjustment,basedonhisto

25、ricaldata,isthefollowing:oNoadjustmentismadeduringthefirstfiveyearsofthefurnacelifeoFromthe6thyear,thefurnaceconsumes1%moreperyear:I,“eo=Thef,.03,aNotetherightmosttermisonexponential,whichmeansitisaacompond-interest-like,formula.Thisagingeffecthastobecalculatedeverydayandtakenintoaccountintothedaily

26、specifictheoreticalconsumption.SteP5:CaICUIatethemonthlytheoreticalSPeCifiCCOnSUmPtionTocalculatethespecifictheoreticalconsumptionoveraperiod(inthiscasetheentiremonth),wecalculatetheweightedaverageofthespecifictheoreticalconsumptionforeachdayusingthedailyequivalentpullat20%culletastheweighingfactor:

27、ZEqiiivaIenPulKd(Iy)l-The(day),Theo(month)=,wnllj/EquivaienPnlHday),.ThiscorrespondstotheTheoreticaltermintheKPIequation.Calculatingtheequivalentfurnacepullat20%culletWhenconvertingtheenergymeasuresintospecificenergymeasures,theequivalentfurnacepullat20%culletisused.Itiscalculatedusingthefollowingfo

28、rmula:EquivalentPuU=Pull-il二”,Where%Culletistheculletrate,beingafractionbetween0and1.OEE-Transformationlines1.DefinitionTRS(OEE)=YieldEfficienyPnnluctionrate=ProductivetinieHU(1.aminatingandMirrorHPTRS(OEE)=YieldEfficientHuIHG/0出”HP:HoursofproductionHU:Hoursofutilisation HG:Hoursofregularmaintenance

29、 Productionrate=HP/HUOthervariants：TRG=TRSUtmSaliatrate=ProductivetimeHF HF:OpenedhoursofthelineTRE=TRGSaturationrate=PmductivetimeHD HD:Hoursavailable2.Furtherexplanation&lossesdistributionIHoUrSavMlabl=HDHoursofl*Jerctwh二】小CgYjHRIOpndhoursofthlin.HFHOU6ofkresl竺竺HIIHoursTriaklHEfoHR=Hoursofshortage

30、s：-strike-shortageofglassintheplantOpenedhoursoftheline:HF=HD-(HS+HR)1.inenotengagedinproductionoHI=Hoursofinvestments:installationandstart-upofanewequipmentoHE=Hoursoftrials：timededicatedtotrials：- Processimprovement- Productimprovement- Transferofproduct- NewproductdevelopmentoHG=Hoursofplannedreg

31、ularmaintenance:- Yearlymaintenance- Cleaningoftheline- Regularmaintenancechangesofsmallequipments)Hoursofutilization;HU=HF-(HI+HE+HG)UtilisationofthelineoHM=Hoursofset-up:- HMPC=Timenecessarytogofrom1producttoanother,- HMA=Timenecessarytosetthequalityofproductsafteraccidentaldowntimes,- HMG=Timenec

32、essarytosetthequalityofproductsafterregularmaintenanceoHN=1.ossesduetotheprocess(notpossibletoavoidduetotheprocessit-self):- Timechangingstillagesentranceoflinewithoutproductchange)- Timeforchangingstillagesexitoftheline(stacker)- Timeforremovingspacerentranceofline(loader)- Timetoputspacerexitofthe

33、line(stacker)- Timeforremovingcoversheetentranceofline(loader)- Timeforchangingcoversheetstillageexitoftheline(stacker)- Timeforchangingsuctioncupsprotection(loaderandstacker)- TimeforchangingPVBrolls(1.aminatinglines)- OthersoHA=1.ossesduetotechnicalissues:-Equipments,failureslistperequipmentlevelm

34、ax)withorw/oimpactonglasslosses- Rawmaterialsissues(viscosityofpaint,wavinessofPVB,etc.)- BrokenglassremovingoHO=1.ossesduetoorganizationissues:- personnelissues(illness,lunchtime),- wrongqualityofrawglass- warehouseissues(delayinsupplyofglasstotheline)- shortagesofrawmaterialsHoursofproduction:HP=H

35、U-(HM+HN+HA+HO)ThesedefinitionsleadtothefollowingequivalenceswithactualBIP(report)ofcoatersandlaminatinglines:CurrentcoaterBIPNewdefinitionCurrent1.aminatingBIPHSMHSHGlHSVHRHGlandHAlHSHO/HSHGlHGHGHG2HNHNHNHAHAHA2HAHOHAl Production/Utilization/SaturationratesoProductionrate=HP/HUoUtilizationrate=HU/H

36、FoSaturationrate=HF/HD YieldoGlassIn(VE):Allglassputinsidetheline(exceptglasswithalreadyacoatforcoaterlines)oGoodglass(VB):m1producedofgoodquality,putinsidethewarehouseoGlassforsetupVM)(coaters):Quantityofglassputinsidethelineusedtosetuptheline.Alltypeofglassmustbetaken(exceptglasswithalready1coat)o

37、VA/VN(coaters)：glassincoating-linewhenanaccidenthappens,mustbeexcludedfromyield(OEE!Willbewrong).VAisalsotheadjustment-glassafterHAo1.ossesduetoqualityofrawglass(Q1.):glassrejectedduetoqualityofrawglass(markeddefectsfromfloatorcoater,wrongqualityofglassprocessed)oGeometricallosses(G1.)(off-linecutti

38、ng)：trimsrejectedduetonon-entirenumbersofchildsheetscutinP1.FsheetoQualitylosses:detailsofqualityreasonsforlosses:eachtypeoftransformationlinewillgiveitsownlistofpossibledefectsoYield(Mirror&1.aminatinglines)=VB/VEoYield(Coaters)=VB/(VE-VM-VA-VN)oYield(Off-linecutting)=VBZ(VE-Q1.-G1.)Efficiency(6cyc

39、letimelosses)o1.inespeed:nominalspeedoftheline.Tobedefinedforeachproduct.oCycletime(off-linecutting):timebetween2P1.F-calculatedpercuttingplanbasedoncycletimeof3equipmentsoTheoreticalHP:TheoreticalnumberofhoursofproductionnecessarytoprocesstheglassputinthelineMainlossesduetodecreaseoflinespeed,space

40、betweenplatesorequipmentworkingwithacycletimelowerthanspecifications.Tobedefinedforeachproduct.oTheoreticalHP(Coaters)=(VE-VM-VA/N)/1.inespeedoTheoreticalHP(Mirrors)=VE/1.inespeedoTheoreticalHPOff-linecutting,1.aminating)=VECycletimeoEfficiency=(TheoreticalHP)/RealHPPRODUCTMTY-Transformation1.ines1.

41、 DefinitionMH(mnhours)f.1Goodpn)duetion(m2)rroducliviy=!2. Explanation Goodproduction(m2):goodglassinm7stackedandreadytobesenttotheclient MH=(HoursXHeadcount)+Overtime-Traininghours Headcount:directlabouroftheCoater/1.aminatinglineHours:numberofhoursworkedduringconsideredperiodQUA1.iTYANDPROCESSCONT

42、RO1.C1.AIMS1. Definition0,.*,.Claimsvalue(localcurrency)MgnnClaims*(ppm)=-IO(XXXX)Salesvaiue(iocalcurrency).n,.iClaimsvahtelocalcurrency)ClaumlyZdyt=-I(X)Salesvalue(locuicurrency)Claims(localcurrency):claimspaidduringtheconsideredperiodDdommagement(localcurrency):dedommagementspaidduringtheconsidere

43、dperiodSales(localcurrency):salesmadeduringtheconsideredperiodforalltheproducts：Sekurit,KaPPa,Building-Float,Building-1.owE,Building-SolarControl,Building1.aminated,Building-Mirrors,Building-DecorglassandAlbarino.lonlyforSekuritandAlbarino(Jaroszowiec)2. ExplanationClaim:writtenrequestofrefundmadeby

44、thecustomerduetodefectsfoundintheglass.E.g.:glassdefects,colourdefects,tindefects,opticaldefects,annealingdefects,dimensiondefectsanddefectsorfaultsafterproduction,packaging,loading,storage.3. DistributionbytypeFIOatGlaSSGlassDefectsTinDefectsAnnealingDefectsOpticalColourDefectsDimensionsDefectsMark

45、ingDefectsafterPP1.StorageShipping(Breakage!OtherDefectsCOatedGIaSSPre-process-FloatRawMaterial-AnnealingPost-ProcessDefectsafterPP1.(PP1.=Productian,Packaging,-1.oading)-Storage-ShipmentDebrisScratchesChemicalResistanceMechanicalResistanceTemperingIssuesOthers1.amInatedPollutionCutting/FlatnessBubb

46、lesOthersMirrorSProcessMetalcoatingdefectsPaintingdefectsDEeORG1.ASSGlassDefects:StonesBubblesA1.BAmNOGlassDefects:Stones-BubblesCorrosion-MarkingIssuesColourissuesOthersGlass(floatdefects)-FloatDefectsOpticalDefectsAnnealingDefects-SizeColourissuesWarehouse,shipment,defectsaftermanufacturing-StorageproblemsDefectsaftermanufacturing,packaging,loading.-Transportissues(breakage)-OthersColourDefectsFormingDefectsOpticalDefectsAnnealingDefectsDimensionDefectsThicknessdefectsMarkingDefectHandling,Packaging,1.oadingProblemsSto