- Life-Cycle-Performance for Manufactures of Production Facilities -

Transcription

1 - Life-Cycle-Performance for Manufactures of Production Facilities - Prof. Dr.-Ing. Jürgen Fleischer, Dipl.-Ing. Jan Rühl, Dipl.-Wi.-Ing. Richard Ladenburger Zurich, 27 August 2007 Presentation of results of the research project: LICMA. LICMA is funded by the Bundesministerium für Wirtschaft und Technologie.

2 Content Initial Situation Objectives Approach Summary

4 Initial Situation - Industry Requirements - Life-Cycle-Costs (LCC) for a time period of 10 years of a printing machine in use by the company MAN: 7,82 5,32 2,55 Staff Costs 11,14 17,02 Krawitz, Augsburg, ,15 Acquisition Costs Maintenance Costs Tool Costs Energy and Running Costs Other Costs Initial Situation: Life-Cycle-Costs (LCC) are a main factor for the purchase decision. Every machine user is developing his own system of measurement of the LCC. High effort for the machine builder to calculate his proposition. That s why a standardization d at for the machine builder is necessary. the base is development of a new approach for the machine user.

6 Objectives Development of a ratio for the measurement and comparison of production facilities. f(x)= Approach for the prognosis of Life-Cycle-Performance of the machine builder s point of view. Providing a structured approach for the Life-Cycle-Performance Management for the machine builder.

8 Approach - Ratio for measurement - What is the main point in which a machine user is interested before his new purchase? Unit Price Approach for the machine builder: Creating a new Index: LCP. Benefit LCP = LC Costs LC

9 Approach - Ratio for measurement - To be able to calculate the unit price, we need Ratios of the production facility: LCP = Life-Cycle-Performance. OEE = Overall Equipment Effectiveness. LCC = Life-Cycle-Costs. Statistical Methods for the calculation of the OEE of machine components and the complete machine: Weibull-Analysis, FTA, FME(C)A, Quality-Simulation, Methods for the calculation of LCC: VDI 2884, DIN , VDMA 34160, Data of the machine: Sources and fields of data for the determination of the LCP Index.

10 Approach - Prognosis of LCP - Availability * * MTBF, MTTR, Performance Rate Procedure, Organization, Quality Rate Quality Problems, Buildings ngs and and Infra astructure Machinery Installationon Tr Training-Co Costs Alteration and MoM odification Ene nergy, Tools ols Labor-Cos osts * Overall Equipment Effectiveness (OEE) Mainten enance-cost st (Person) n) Maintena enance-cost st (Material) )al) Initial-Costs Operating-Costs Costs Theoretical Output Life-Cycle-Cost (LCC) Actual Output Unit Price

11 Approach - Prognosis of LCP - Estimation of the LCC Estimation of the benefit Availability * Buildings s and Infastructure Macninery Installation raining-costs Alteratio on and Modification Energy, Tools Labour-Costs Maintena nance-cost (Person) )) Maintena ance-cost (Material e l)l) Initial-Costs Operating-Costs * Performance Rate Quality Rate TrT * Overall Equipment Effectiveness (OEE) Theoretical Output Life-Cycle- Cost Actual Output Costs = Pr d d LC [ Costs ] oduct independing LC Costs dt Pr depending ( t ) oduct Δ oduct t oduct Pr Pr + ( Δ t Pr oduct ) oduct Benefit = Output theoretical OEE Pr LC Pr oduct 1 FixedCycle Output theoretical = Δ t Pr OEE Pr oduct = Δ t Pr OEE ( t ) dt oduct Δ t Pr oduct oduct

12 Approach - Prognosis of LCP - Life-Cycle-Cost Unit Price Output (OEE) LCP = LC LC 1 Benefit OEE( t) dt Pr oduct FixedCycle Δt Pr oduct = Costs [ Costs ] Pr oduct independing + Costs Pr oduct ( t) dt Pr depending ) LC Pr oduct Δt Pr oduct

13 Approach - Prognosis of LCP - OEE = Availability * Performance Rate * Quality Rate Main considered aspects: Reliability Downtime Failures Data Number of failures MTBF Running Breakdown Running MTTR Breakdown Running Failure Occurrence Failure Communication Technician on-site Failure detected Resources are available Repaired Starting

14 Approach - Prognosis of LCP - Machine Structure Data Collection Reliability Model and Analysis Analysis FMEA / Experts After Sales Service Builder Malfunction behavior (Weibull analysis) Test & Simulation Spare part sales Operating data Maintenance data Machine Mac chine Us ser Reliability Parameters & Period of Repair

15 Approach - Perspective: Structured approach Condition Monitoring - The two presented dimensions for the calculation of the unit price are: Life-Cycle-Costs Unit Price Productivity (OEE) Goal: Model for prediction and controlling of the reliability and maintainability of machines and plants over the Life-Cycle. Third Dimension: Life-Cycle-Costs Costs Productivity (OEE) Monitoring Life-Cycle- Performance Management

16 Approach - Perspective: Structured approach Condition Monitoring - Life-Cycle-Performance Management: Reference model (3 ranks). Monitoring MPM MPM MPM MPM Productivity it Life-Cycle-Costs Record Synchronize R&D Synchr. Markt, R&D actual actua al Markt, R&D Analysen KVP Controlling Kunden- OEE Felddaten- OEE OEE OEE Auswertung Maßnahmen Review erfassung LCC Felddatenerfassung LCC LCC LCC Auswertung Maßnahmen Review Interpretation Actions Review Synchr. Analysen KVP Controlling Analysis MPM- Amelioration spez. Controlling Analyse Prognose Risikoanalyse Structural Customer Risk- analysis requirements analysis actual target Risikoanalyse Pflichtenheft Lastenheft actu targe ual et targe et tar rget actual actual target target

18 A A B C D E B 1 B 2 B B 1.1 B 1.2 B 2.1 B B B Summary Ratio for measurement of performance of production facilities: OEE Benefit LCP = LC Costs LC = Availability PerformanceRate QualityRate Data collection for the prognosis of the Life-Cycle-Performance: Prognosis of Life-Cycle-Performance for the machine builder: Providing a structured approach for the machine builder: Operating Data Maintenance Data Monitoring MPM MPM MPM MPM Reliability-Data-Model Productivity Life-Cycle-Costs OEE Felddatenerfassung OEE OEE OEE Auswertung Maßnahmen Review LCC Felddatenerfassung LCC LCC LCC Auswertung Maßnahmen Review actuel actuel After-Sales Service Dimensioning Spare Part Sales Value-Analysis Expert-Extimation / FMEA Test- & Simulation-Data Machine Manufacture Machine Tool Operator Record Synchr. R&D Markt, R&D Structural analysis actuel Analysen KVP Controlling Customer requirements Risikoanalyse Riskanalysis actuel target Interpretation Actions Review Synchr. Analysen KVP Controlling Synchronize Kundenspez. Markt, Analysis MPM- Amelioration Controlling Risikoanalyse R&D Analyse Prognose Pflichtenheft Lastenheft target act targ tuel rget target actuel target target

19 Questions? Thank you very much for your attention! Prof. Dr.-Ing. Jürgen Fleischer Dipl.-Ing. Jan Rühl Dipl.-Wi.-Ing. Richard Ladenburger wbk Institute for Production Science University of Karlsruhe (TH) Kaiserstr. 12 D Karlsruhe Tel.: +49 (721) Fax: +49 (721)