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© 2006 Prentice Hall, Inc.

Additional Chapter II KPI’s. © 2006 Prentice Hall, Inc. Outline. Key Performance Index Manufacturing KPI’s Productivity Quality Cost Delivery Safety Morale. Outline – Continued. Uses of KPI’s MOTSAP. Learning Objectives. When you complete this chapter, you should be able to:

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© 2006 Prentice Hall, Inc.

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  1. Additional Chapter II KPI’s © 2006 Prentice Hall, Inc.

  2. Outline • Key Performance Index • Manufacturing KPI’s • Productivity • Quality • Cost • Delivery • Safety • Morale

  3. Outline – Continued • Uses of KPI’s • MOTSAP

  4. Learning Objectives When you complete this chapter, you should be able to: Identify or Define: • Key Performance Index • Manufacturing KPI’s • Available time for production • Operation time • Downtime

  5. Learning Objectives When you complete this chapter, you should be able to: Describe or Explain: • KPI’s in Manufacturing • Causes of Downtime • Uses of KPI’s

  6. Key Performance Index • Measurable quantity • Indicator that reflect the operation results • Management tool

  7. Manufacturing KPI’s • Indicators used to indicate manufacturing performance • 6 groups of KPI’s • Productivity • Quality • Cost • Delivery • Safety • Morale • Production performance • Quality performance • Cost performance • Delivery performance • Safety and Environmental • Employee collaboration

  8. Planning Production Sourcing Delivery Manufacturing Manufacturing KPI’s Customer & Consumer Supplier Customer & Consumer Development Products & Processes Development

  9. Productivity KPI’s Total Time Available Time Holiday Unused Time No plan Used Time Planned maintenance Operation Time Planned Halt Time Set up, stop sequence Production Time Routine Production Stoppage Unexpected Stoppage Breakdown, part short Effective Time Performance losses Net-utilized time Idle time, speed loss, defect

  10. Productivity KPI’s Total Materials Total Produced Product Waste Defect Product that can be sold Priority Product By Product Good Product Rework

  11. Man-Hours for production Total Man-Hours Total Assigned Man-Hours Break, Meeting Net Working Man-Hours Idle time, Motion Efficient Man-Hours Unbalanced line, Lack of automation Valued Man-Hours Monitoring, Adjustment

  12. 1 Actual Production Speed Production Volume Man-hour Number of Self-Fixing Number of Breakdown Productivity KPI’s • Actual Cycle Time = • Labor Productivity = • AM Ratio =

  13. Actual Output - Defect x 100 Actual Output Rework Waste x 100 x 100 Actual Output Actual Output Productivity KPI’s • %Quality Rate = • %Rework = • %Waste =

  14. Theoretical Cycle Time x Actual Output x 100 Operation Time Operation Time - Downtime x 100 Operation Time Productivity KPI’s • %Performance Rate = • %Availability Rate =

  15. %Availability x %Performance x %Quality Rate 10,000 Productivity KPI’s • %OEE (Overall Equipment Efficiency =

  16. OEE เป็นดัชนีชี้วัดที่รวมเอาความสามารถทุกด้านของเครื่องจักร • %Availability x %Performance x %Quality/10,000 • %Availability = ความสามารถในการทำให้เครื่องอยู่ในสภาพพร้อมใช้งานอยู่ตลอดเวลา • %Performance = ความสามารถในการทำให้เครื่องจักรสามารถทำงานได้เต็มกำลังการผลิตอยู่ตลอดเวลา • %Quality = ความสามารถในการทำให้เครื่องจักรผลิตสินค้าได้อย่างมีคุณภาพตลอดเวลา

  17. Actual Output - Defect x 100 • %Performance Rate = • %Quality Rate = Actual Output Theoretical Cycle Time x Actual Output x 100 Operation Time • %Availability Rate = Operation Time - Downtime x 100 Operation Time OEE

  18. OEE (ตัวอย่างการคำนวณ) เครื่องจักรหนึ่งในโรงงานถูกใช้งานในการผลิตสินค้าจำนวน 500 ชิ้น ให้แล้วเสร็จใน 1 วัน ปรากฏผลดังนี้ • มีเวลาในการผลิตทั้งหมด 480 นาที • มีกรณีเครื่องจักรเสียระหว่างการทำงาน 30 นาที • ผลิตสินค้าได้ 500 ชิ้น เป็นของเสีย 9 ชิ้น • กำหนดรอบเวลามาตรฐานสำหรับสินค้าชนิดนี้เท่ากับ 0.8 นาที/ชิ้น

  19. OEE • %Availability = (480 – 30)/480= 94% • %Performance =(0.8 x 500)/450 = 89% • %Quality = (500 – 9)/500 = 98% • %OEE = (94 x 89 x 98)/10,000 = 82%

  20. Number of Minor Stoppage = Number of Stoppage Below10 min. and no Change of Spare Part Productivity KPI’s Breakdown Time x 100 • %Breakdown = Operation Time Number of Breakdown • Breakdown Times =

  21. Weekly plan 1500 4000 3000 20 hrs 8 2000 2500 4 Production Planned Maintenance Repair Time No Plan MTTR, MTBF • MTTR = Mean Time To Repair เวลาเฉลี่ยที่ใช้ในการซ่อมคืนสภาพ • MTBF = Mean Time Between Failure เวลาเฉลี่ยของความสามารถเดินเครื่องจักรต่อเนื่องโดยไม่หยุด อันเนื่องมาจากความเสียหาย

  22. 4.25-4.35 3.30-3.50 35 30 60 10 20 22.25-23.00 21.50-22.20 3.20-4.20 610 22.00-8.10 Example

  23. Productivity KPI’s Available Time x 100 • %Machine Availability = Total Time Used Time x 100 • %Machine Utilization = Total Time Effective Time x 100 • %Operation Efficiency = Operation Time

  24. USL - LSL • Capability Index = 6SD Quality KPI’s • Average Rejection Case by Customer • Average Rejection Case by QA USL = Upper Specification Limit LSL = Lower Specification Limit SD = Standard Deviation Uncontrollable Controllable Good Control 1.33 1.00

  25. Quality KPI’s • Number of Quality Kaizen Total Rejection x 100 • %Rejection = Actual Output

  26. Cost KPI’s Cost used for conversion of Raw material to Product • Conversion Cost = • Production direct, indirect and service cost. • Purchasing, Planning and Supply support cost * Usually showed in unit cost • Cost of Waste Disposal Cost of Poor Quality + QA Conversion • Cost of Quality =

  27. Cost KPI’s Cost of Spare Part Inventory • Inventory of Spare Part = Cost of Raw Material and Finished Goods Inventory • Inventory of Material = Cost of Work-In-Process Inventory • Inventory of WIP = * Usually showed in % of Produced Product

  28. Cost KPI’s • Production Direct Cost = Direct Labor + Depreciation + Other Direct Product Volume • Production Indirect Cost = Indirect + Other Indirect Product Volume • Repair & Maintenance Cost

  29. Delivery KPI’s Actual Output x 100 • %Output Reliability = Planned Output Number of Target Hit x 100 • %Plan Attainment = Number of Production Run

  30. Safety KPI’s • %Accident Frequency Rate = Lost Working Time + Restricted Working Time Total Working Time • Number of Safety Suggestion • Number of Unsafe Correction • Number of Incident • Number of Accident

  31. Morale KPI’s Absent Employee x 100 • %Absent = Total Employee Number of Kaizen • Kaizen Rate = Total Employee Total Training Hour • Training Rate = Trained Employee

  32. Using of KPI’s 5W-1H • What – data should be collected • Where – location of machine/working place • Who – take action to report KPI • When – timing and frequency of report • Why – meaning of KPI • How – to collect data

  33. Using of KPI’s To produce the best quality product in Thailand with lowest cost MOTSAP • Reduce customer rejection • Reduce defect • Increase productivity • Reduce labor cost Policy Mission Objective • %Rejection = 0 • Reduce %Defect 50% • Increase %OEE 5% • Increase labor productivity 30% • Reduce downtime 50% Target Strategy Action Quality kaizen, TPM, Inspection Establish projects Plan Establish plans

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