CN105096054A - Injection molding machine management decision method based on overall equipment capacity and overall equipment effectiveness - Google Patents
Injection molding machine management decision method based on overall equipment capacity and overall equipment effectiveness Download PDFInfo
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention discloses an injection molding machine management decision method based on overall equipment capacity and overall equipment effectiveness. The method comprises: evaluating the overall equipment capacity of an injection molding machine according to an equipment reliability index, a product quality index and an equipment energy conservation index; evaluating the overall equipment effectiveness of the injection molding machine, and constructing a two-dimensional decision matrix composed of the evaluated overall equipment capacity and overall equipment effectiveness; recognizing the capacity loss reason in production according to the constructed two-dimensional decision matrix, and making an injection molding machine management decision according to the recognized result. According to the method, the evaluation of the overall equipment capacity is added, the overall equipment capacity of the injection molding machine is scientifically and comprehensively evaluated from three aspects, namely product quality, equipment reliability and energy conservation, and the capacity loss reason in production is recognized by comprehensive analysis of the overall equipment effectiveness and the overall equipment capacity, so that a management decision support is provided and the method is more scientific, comprehensive and objective. The method can be widely applied in the field of equipment management methods.
Description
Technical field
The present invention relates to device management method field, especially a kind of injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment.
Background technology
In the traditional manufacture comprising Injection Industry, the most original device management method mainly adopts equipment availability and failure rate index to ensure the fault of the intact of equipment and opertaing device, there is certain limitation, can not the service efficiency situation of consersion unit comprehensively.Current is overall equipment efficiency.comprehensive efficiency of equipment management method by the widely used device management method in the whole world.Overall equipment efficiency.comprehensive efficiency of equipment (OverallEquipmentEffectiveness; i.e. OEE); its essence is the ratio of the actual production capacity of single device production capacity theoretical with it; overall equipment efficiency.comprehensive efficiency of equipment reflects three class losses of production capacity in actual production; comprise: loss stop time caused because of equipment failure, shortage of raw materials etc.; because of the speed of production loss that equipment attrition, material are defective, human error causes, and the mass loss caused because product is defective.Overall equipment efficiency.comprehensive efficiency of equipment than traditional measure science more, can for improving equipment use efficiency, carry out equipment control, reduce equipment effectiveness loss reference is provided, be thus subject to international widespread use.According to the standard of international uniform, world-class manufacturing industry, the index of its overall equipment efficiency.comprehensive efficiency of equipment should be greater than 85%.From current domestic enterprise incomplete statistics data, although the overall equipment efficiency.comprehensive efficiency of equipment difference of different industries is comparatively large, on the whole, overall equipment efficiency.comprehensive efficiency of equipment, greatly about about 70%, still remains at low levels.Overall equipment efficiency.comprehensive efficiency of equipment as one independently survey instrument, its measure be the ratio of certain the actual production capacity of equipment relative to its theoretical production capacity, its calculate be produce in exist stop time loss, speed of production loss and this three class of mass loss lose.But each class loss in above-mentioned three class losses all contains the impact of the multiple factors such as people, machine, material, so single overall equipment efficiency.comprehensive efficiency of equipment concept can only measure the size of capacity loss, can not isolate the reason causing capacity loss.Overall equipment efficiency.comprehensive efficiency of equipment can provide certain reference for improving plant efficiency, but improves plant efficiency as which aspect from " man-machine material method ring ", and overall equipment efficiency.comprehensive efficiency of equipment just cannot reoffer reference, has certain limitation.
Summary of the invention
In order to solve the problems of the technologies described above, the object of the invention is: a kind of science, comprehensively and is objectively provided, based on the injection machine management decision method of equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment.
The technical solution adopted for the present invention to solve the technical problems is:
Based on the injection machine management decision method of equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment, comprising:
S1, to evaluate according to equipment dependability index, product quality indicator and the device energy conservation index equipment complex ability to injection machine;
S2, the overall equipment efficiency.comprehensive efficiency of equipment of injection machine to be evaluated, and build the two-dimentional decision matrix be made up of the equipment complex ability evaluated and overall equipment efficiency.comprehensive efficiency of equipment;
S3, identify capacity loss reason in production according to the two-dimentional decision matrix built, and carry out injection machine management decision according to the result identified.
Further, described equipment dependability index is failure rate, and described product quality indicator is Measure of Process Capability C
pk, described device energy conservation index is consumption rate.
Further, described step S1, it comprises:
S11, determine the evaluation criterion of equipment dependability index, product quality indicator and device energy conservation index;
S12, determine the weight matrix of equipment dependability index, product quality indicator and device energy conservation index;
S13, determine the fuzzy evaluating matrix that is made up of degree of membership according to evaluation criterion;
S14, weight matrix to be multiplied with fuzzy evaluating matrix, to obtain grade evaluation matrix, and according to the equipment complex ability rating of grade evaluation matrix determination injection machine.
Further, described step S12, it comprises:
S121, by expert to these three indexs of equipment dependability index, product quality indicator and device energy conservation index carry out tax weigh;
S122, utilization analytical hierarchy process are analyzed the result that expert composes power, finally draw the weight matrix W={0.45 of equipment dependability index, product quality indicator and device energy conservation index, 0.33,0.22}, wherein, 0.45 is the weight of equipment dependability index, and 0.33 is the weight of product quality indicator, and 0.22 is the weight of device energy conservation index.
Further, described step S13, it comprises:
S131, set up evaluation points set and opinion rating set, the expression formula of described evaluation points set U and opinion rating set V is respectively:
U={u
i| i=1,2,3}={u
1, u
2, u
3, V={v
j| j=1,2,3}={v
1, v
2, v
3, wherein, u
1for failure rate, u
2for C
pk, u
3for consumption rate, v
1for height, v
2for in, v
3for low;
S132, set up different evaluation factor u
ito different evaluation grade v
jsubordinate function v
j(u
i);
S133, according to set up subordinate function v
j(u
i) obtaining the fuzzy evaluating matrix R that is made up of degree of membership, the expression formula of described fuzzy evaluating matrix R is:
Further, the subordinate function v of described foundation
j(u
i) comprise failure rate u
1respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
1), v
2(u
1) and v
3(u
1), represent C
pku
2u respectively
2respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
2), v
2(u
2) and v
3(u
2), consumption rate u
3respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
3), v
2(u
3) and v
3(u
3), described subordinate function v
1(u
1), v
2(u
1) and v
3(u
1) expression formula be:
Described subordinate function v
1(u
2), v
2(u
2) and v
3(u
2) expression formula be:
Described subordinate function v
1(u
3), v
2(u
3) and v
3(u
3) expression formula be:
Further, described step S14, it comprises:
S141, be multiplied with fuzzy matrix R by weight matrix W, obtain grade evaluation matrix B, the expression formula of described grade evaluation matrix B is: B=WR=(b
1, b
2, b
3);
B in S142, comparison scale Evaluations matrix B
1, b
2and b
3the size of these three elements, and according to the equipment complex ability rating of the maximal value determination injection machine in these three elements.
Further, described step S142, it is specially:
B in comparison scale Evaluations matrix B
1, b
2and b
3the size of these three elements, if the maximal value in these three elements is b
1, then the equipment complex ability rating of injection machine is high; If the maximal value in these three elements is b
2, then during the equipment complex ability rating of injection machine is; If the maximal value in these three elements is b
3, then the equipment complex ability rating of injection machine is low.
Further, described step S2, it comprises:
S21, judge that whether the overall equipment efficiency.comprehensive efficiency of equipment of injection machine is higher than 85%, the grade of the overall equipment efficiency.comprehensive efficiency of equipment if so, then evaluated is for high, otherwise the grade of the overall equipment efficiency.comprehensive efficiency of equipment then evaluated is low;
S22, build the two-dimentional decision matrix be made up of the equipment complex ability evaluated and overall equipment efficiency.comprehensive efficiency of equipment.
Further, described step S3, it is specially:
Identify the capacity loss reason in production according to the concrete grade of equipment complex ability in two-dimentional decision matrix and overall equipment efficiency.comprehensive efficiency of equipment, and carry out injection machine management decision according to the result identified:
If the grade of equipment complex ability is low and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then alarm causes production efficiency low because of machine performance difference, and stops at once producing and carrying out machine performance improvement;
If the grade of equipment complex ability be in and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then check that the low reason of production efficiency is that the general or equipment of equipment complex performance occurs abnormal with other factor;
If the grade of equipment complex ability is high and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then alarm machine is functional but cause production efficiency low because equipment there are serious problems with other factor;
If the grade of equipment complex ability is low and the grade of overall equipment efficiency.comprehensive efficiency of equipment is height, then alarm causes high cost because machine power consumption is excessive, is badly in need of the energy saving improving machine;
If the grade of equipment complex ability be in and the grade of overall equipment efficiency.comprehensive efficiency of equipment for high, then show that equipment is with other factor no problem, need to check whether emphatically that energy saving because of machine is abnormal and cause production efficiency low;
If the grade of equipment complex ability is high and the grade of overall equipment efficiency.comprehensive efficiency of equipment is height, then should maintain current state and proceed to produce.
The invention has the beneficial effects as follows: on the basis of overall equipment efficiency.comprehensive efficiency of equipment evaluation, add equipment complex merit rating, the equipment complex ability of injection machine is evaluated all sidedly from product quality, equipment dependability and energy saving three aspect science, and the capacity loss reason identified by the comprehensive analysis of overall equipment efficiency.comprehensive efficiency of equipment and equipment complex ability in production, thus provide decision support for how improving plant efficiency with the equipment control carrying out science, solve the problem that prior art cannot isolate capacity loss reason, more science, comprehensive and objective.
Accompanying drawing explanation
Below in conjunction with drawings and Examples, the invention will be further described.
Fig. 1 is the overall flow figure of the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment;
Fig. 2 is the process flow diagram of step S1 of the present invention;
Fig. 3 is the process flow diagram of step S12 of the present invention;
Fig. 4 is the process flow diagram of step S13 of the present invention;
Fig. 5 is the process flow diagram of step S14 of the present invention;
Fig. 6 is the process flow diagram of step S2 of the present invention;
Fig. 7 is the embodiment of the present invention one equipment complex merit rating factor structure figure;
Fig. 8 is 6 quadrant schematic diagram that the embodiment of the present invention one is marked off by two-dimentional decision matrix.
Embodiment
With reference to Fig. 1, based on the injection machine management decision method of equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment, comprising:
S1, to evaluate according to equipment dependability index, product quality indicator and the device energy conservation index equipment complex ability to injection machine;
S2, the overall equipment efficiency.comprehensive efficiency of equipment of injection machine to be evaluated, and build the two-dimentional decision matrix be made up of the equipment complex ability evaluated and overall equipment efficiency.comprehensive efficiency of equipment;
S3, identify capacity loss reason in production according to the two-dimentional decision matrix built, and carry out injection machine management decision according to the result identified.
Be further used as preferred embodiment, described equipment dependability index is failure rate, and described product quality indicator is Measure of Process Capability C
pk, described device energy conservation index is consumption rate.
With reference to Fig. 2, be further used as preferred embodiment, described step S1, it comprises:
S11, determine the evaluation criterion of equipment dependability index, product quality indicator and device energy conservation index;
S12, determine the weight matrix of equipment dependability index, product quality indicator and device energy conservation index;
S13, determine the fuzzy evaluating matrix that is made up of degree of membership according to evaluation criterion;
S14, weight matrix to be multiplied with fuzzy evaluating matrix, to obtain grade evaluation matrix, and according to the equipment complex ability rating of grade evaluation matrix determination injection machine.
With reference to Fig. 3, be further used as preferred embodiment, described step S12, it comprises:
S121, by expert to these three indexs of equipment dependability index, product quality indicator and device energy conservation index carry out tax weigh;
S122, utilization analytical hierarchy process are analyzed the result that expert composes power, finally draw the weight matrix W={0.45 of equipment dependability index, product quality indicator and device energy conservation index, 0.33,0.22}, wherein, 0.45 is the weight of equipment dependability index, and 0.33 is the weight of product quality indicator, and 0.22 is the weight of device energy conservation index.
With reference to Fig. 4, be further used as preferred embodiment, described step S13, it comprises:
S131, set up evaluation points set and opinion rating set, the expression formula of described evaluation points set U and opinion rating set V is respectively:
U={u
i| i=1,2,3}={u
1, u
2, u
3, V={v
j| j=1,2,3}={v
1, v
2, v
3, wherein, u
1for failure rate, u
2for C
pk, u
3for consumption rate, v
1for height, v
2for in, v
3for low;
S132, set up different evaluation factor u
ito different evaluation grade v
jsubordinate function v
j(u
i);
S133, according to set up subordinate function v
j(u
i) obtaining the fuzzy evaluating matrix R that is made up of degree of membership, the expression formula of described fuzzy evaluating matrix R is:
Be further used as preferred embodiment, the subordinate function v of described foundation
j(u
i) comprise failure rate u
1respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
1), v
2(u
1) and v
3(u
1), represent C
pku
2u respectively
2respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
2), v
2(u
2) and v
3(u
2), consumption rate u
3respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
3), v
2(u
3) and v
3(u
3), described subordinate function v
1(u
1), v
2(u
1) and v
3(u
1) expression formula be:
Described subordinate function v
1(u
2), v
2(u
2) and v
3(u
2) expression formula be:
Described subordinate function v
1(u
3), v
2(u
3) and v
3(u
3) expression formula be:
With reference to Fig. 5, be further used as preferred embodiment, described step S14, it comprises:
S141, be multiplied with fuzzy matrix R by weight matrix W, obtain grade evaluation matrix B, the expression formula of described grade evaluation matrix B is: B=WR=(b
1, b
2, b
3);
B in S142, comparison scale Evaluations matrix B
1, b
2and b
3the size of these three elements, and according to the equipment complex ability rating of the maximal value determination injection machine in these three elements.
Be further used as preferred embodiment, described step S142, it is specially:
B in comparison scale Evaluations matrix B
1, b
2and b
3the size of these three elements, if the maximal value in these three elements is b
1, then the equipment complex ability rating of injection machine is high; If the maximal value in these three elements is b
2, then during the equipment complex ability rating of injection machine is; If the maximal value in these three elements is b
3, then the equipment complex ability rating of injection machine is low.
With reference to Fig. 6, be further used as preferred embodiment, described step S2, it comprises:
S21, judge that whether the overall equipment efficiency.comprehensive efficiency of equipment of injection machine is higher than 85%, the grade of the overall equipment efficiency.comprehensive efficiency of equipment if so, then evaluated is for high, otherwise the grade of the overall equipment efficiency.comprehensive efficiency of equipment then evaluated is low;
S22, build the two-dimentional decision matrix be made up of the equipment complex ability evaluated and overall equipment efficiency.comprehensive efficiency of equipment.
Be further used as preferred embodiment, described step S3, it is specially:
Identify the capacity loss reason in production according to the concrete grade of equipment complex ability in two-dimentional decision matrix and overall equipment efficiency.comprehensive efficiency of equipment, and carry out injection machine management decision according to the result identified:
If the grade of equipment complex ability is low and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then alarm causes production efficiency low because of machine performance difference, and stops at once producing and carrying out machine performance improvement;
If the grade of equipment complex ability be in and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then check that the low reason of production efficiency is that the general or equipment of equipment complex performance occurs abnormal with other factor;
If the grade of equipment complex ability is high and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then alarm machine is functional but cause production efficiency low because equipment there are serious problems with other factor;
If the grade of equipment complex ability is low and the grade of overall equipment efficiency.comprehensive efficiency of equipment is height, then alarm causes high cost because machine power consumption is excessive, is badly in need of the energy saving improving machine;
If the grade of equipment complex ability be in and the grade of overall equipment efficiency.comprehensive efficiency of equipment for high, then show that equipment is with other factor no problem, need to check whether emphatically that energy saving because of machine is abnormal and cause production efficiency low;
If the grade of equipment complex ability is high and the grade of overall equipment efficiency.comprehensive efficiency of equipment is height, then should maintain current state and proceed to produce.
Below in conjunction with Figure of description and specific embodiment, the present invention is described in further detail.
Embodiment one
With reference to Fig. 1-8, the first embodiment of the present invention:
The present embodiment based on the implementation procedure of the injection machine management decision method of equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment is:
(1) first, set up the factor of evaluation structural drawing of valuator device integration capability, as shown in Figure 7, from equipment dependability, product quality and device energy conservation three aspects, equipment complex ability is assessed.
Equipment dependability refers to the degree of equipment steady operation under defined terms and in official hour; available fault rate (FailureRate) this index is weighed; failure rate can be expressed as the number of stoppages of (week, the moon or year) equipment in the unit interval; the fault of the present embodiment only refers to the fault (as mechanical fault, controller failure etc.) of injection machine self, does not comprise misoperation, of short duration shutdown that the external cause such as under feeding causes.According to priori, the judgment criteria of the present embodiment injection machine reliability step is as shown in table 1:
Table 1 injection machine reliability step evaluation criterion
| Failure rate (secondary/week) | Grade |
| <1/168 | 1 |
| <2/168 | 2 |
| >＝2/168 | 3 |
And product quality can with the Measure of Process Capability C of the key index of product under steady production state
pkweigh, C
pkcomputing formula be:
Wherein, USL is upper specification limit, and LSL is specification lower limit,
for specification average, s is standard deviation, and min is function of minimizing.
If product has multiple C
pkindex, then select minimum C
pkevaluate.
C international at present
pklevel evaluation standard is as shown in table 2 below:
Table 2 injecting products C
pkgrade evaluation standard
| C pk | Grade |
| >＝1.67 | 1 |
| >＝1.33 | 2 |
| <1.33 | 3 |
Energy saving refers to that equipment saves the degree of electric energy in normal working conditions, available consumption rate, and namely the power consumption of product every kilogram is weighed, and the present embodiment is produced raw material used when measuring consumption rate and be should be phenylethylene (ABS, PS or HIPS).According to " specification of the detection of plastic-injection moulding machine energy consumption and ranking " that China Plastics Machinery Industry TIA put into effect in August, 2009, the judgment criteria of injection machine energy-saving is as shown in table 3:
Table 3 injection machine energy-saving grade evaluation standard
| Consumption rate kw*h/kg | Grade |
| <＝0.55 | 1 |
| <＝0.85 | 2 |
| >0.85 | 3 |
(2) after determining the grade evaluation standard of equipment dependability, product quality and device energy conservation three indexs, carry out tax by the expert in 50 injection industry fields to these three indexs to weigh, then use analytical hierarchy process (AnalyticHierarchyProcess) to compose power result to expert to analyze, the weight finally determining these three indexs of equipment dependability, product quality and device energy conservation is respectively 0.45,0.33,0.22.
(3) evaluation points set and class set is set up, evaluation points set U={u
1, u
2, u
3; Opinion rating set is V={v
j| j=1,2,3}={v
1, v
2, v
3.
(4) v is defined
j(u
i) be factor u
iin Grade v
jdegree of membership, set up the subordinate function of different evaluation factor pair different brackets.
Failure rate is to the subordinate function v of opinion rating
1(u
1), v
2(u
1) and v
3(u
1) expression formula be:
Injecting products C
pkto the subordinate function v of opinion rating
1(u
2), v
2(u
2) and v
3(u
2) expression formula be:
Consumption rate is to the subordinate function v of opinion rating
1(u
3), v
2(u
3) and v
3(u
3) expression formula be:
(5) fuzzy evaluating matrix is set up, note v
j(u
i) be r
ij, then the fuzzy evaluating matrix R be made up of degree of membership is:
(6) weight matrix W={0.45,0.33,0.22} are multiplied with fuzzy matrix R, obtain grade evaluation matrix B=WR=(b
1, b
2, b
3), then compare b
1, b
2and b
3size, wherein the maximal value of three correspond to corresponding equipment complex ability rating.Such as, if b
1maximum, then equipment complex ability be v
1(being height); If b
2maximum, then equipment complex ability be v
2(in being); If b
3maximum, then equipment complex ability be v
3(being low).
(7) overall equipment efficiency.comprehensive efficiency of equipment judge with generally acknowledge in the world 85% for boundary, overall equipment efficiency.comprehensive efficiency of equipment higher than 85% is high, overall equipment efficiency.comprehensive efficiency of equipment lower than 85% is low, then the equipment complex ability evaluated and overall equipment efficiency.comprehensive efficiency of equipment are formed two-dimentional decision matrix, as shown in Figure 8, mark off 6 quadrants altogether, correspond to 6 kinds of management decisions and instruct:
Quadrant 1:OEC (i.e. equipment complex ability) is low, and OEE (i.e. overall equipment efficiency.comprehensive efficiency of equipment) is low, gives the alarm: machine performance difference causes production efficiency low, now should stop at once producing, and sets about improving machine even more new engine.
In quadrant 2:OEC, OEE is low, and overall equipment efficiency.comprehensive efficiency of equipment is low, and reason has be equipment complex ability general at two: one; Two is equipment occurs abnormal with other factor (comprising people, material and method etc.), as long in setup time, mold exchange speed is excessively slow, and the too much or material supply of human error not in time etc.Now enhance productivity and start with from above-mentioned two aspects.
Quadrant 3:OEC is high, and OEE is low, gives the alarm: machine performance is fine, but equipment exists serious problems with other factor (comprising people, material and method etc.), causes production efficiency low.Now should check that whether adjusting machine time is long, whether die change speed is excessively slow, and whether human error is too much, and whether quality of material is qualified.
Quadrant 4:OEC is low, and OEE is high, gives the alarm: machine power consumption is excessive and cause high cost, is now badly in need of the energy saving improving machine.
In quadrant 5:OEC, OEE is high, all no problems such as people, machine, material is described, now should focuses on the energy saving of inspection machine.
Quadrant 6: equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment all reach perfect condition, should maintain this state and produce, can improve the plant factor of this machine simultaneously.
Embodiment two
The present embodiment, for the injection machine of a factory mold clamping force 250KN, power 30kw, is described the present invention's applicable cases in practice.
Recording this injection machine at one week internal fault number of times is zero degree, the minimum C of product quality indicator under steady production state
pkbe 1.2, the general assembly (TW) of the phenylethylene product of continuous seepage 50 batches is 1kg, and unit batch time is 1.2s (second need be converted to during calculating hour).
The detailed process of the present embodiment is:
(1) grade of three indexs is first evaluated, u
1=0, by the subordinate function v of failure rate in embodiment one to opinion rating
1(u
1), v
2(u
1) and v
3(u
1) expression formula easily know reliability grade for high; u
2=1.2, by injecting products C in embodiment one
pkto the subordinate function v of opinion rating
1(u
2), v
2(u
2) and v
3(u
2) expression formula draw v
1(u
2)=0, v
2(u
2)=0.2/0.33, v
3(u
2)=1, v
3(u
2) maximum, therefore according to the maximum principle of degree of membership, u
2grade be v
3, namely the grade of stability is low; u
3=(50* unit batch time * injection machine rated power)/weight=[50* (1.2/3600) h*30kw]/1kg=0.5kw*h/kg, by the subordinate function v of consumption rate in embodiment one to opinion rating
1(u
3), v
2(u
3) and v
3(u
3) expression formula easily know energy saving grade for high.
(2) calculate fuzzy evaluating matrix R, all v can be calculated respectively by the subordinate function expression formula of embodiment one
j(u
i), i.e. r
ijvalue, obtaining matrix R is:
(3) comprehensive evaluation is carried out according to maximum membership grade principle, then B=wR=(b
1, b
2, b
3)=(0.67,0.2,0.33), therefore b1 is maximum, and namely this equipment complex ability is high.As calculated, this injection machine overall equipment efficiency.comprehensive efficiency of equipment this week is 70%, and overall equipment efficiency.comprehensive efficiency of equipment is low.Therefore, third quadrant has been dropped on by this injection machine known of the decision matrix in the present invention, the decision guidance now given is: " machine performance is fine; but there are serious problems with other factor (people, material, method) in equipment; and cause production efficiency low, should check: whether adjusting machine time is long, whether die change speed is excessively slow; whether human error is too much, and whether quality of material is qualified ".After checking according to above-mentioned decision guidance, find the situation that really there is operator's over miss, training and relevant rewards and punishments measure should be implemented to this employee immediately.
The equipment control problem that the present invention is directed to injection industry proposes equipment complex ability (OverallEquipmentCapacity, i.e. OEC) management method, scientifically can evaluate the objective circumstances of equipment complex ability, thus the reason of capacity loss in overall equipment efficiency.comprehensive efficiency of equipment evaluation is resolved into machine reason and non-machine reason, further for supvr provides the decision support for the management of separate unit injection machine.
In addition, only evaluate for product quality indicator compared to capacity of equipment index narrow traditionally, the equipment complex ability proposed for separate unit injection machine in the present invention not only considers this factor of evaluation of injecting products quality, more comprehensively incorporated machine reliability and the important factor of energy saving these two, thus to the capacity of equipment of separate unit injection machine carry out science, comprehensively, objective appraisal.In actual production, the reliability of machine is even more crucial than product quality, because only have the continuous seepage of good reliability guarantee safety, the energy saving of machine is also of crucial importance simultaneously, injection machine is the production equipment of highly energy-consuming, vigorously advocate under energy-saving and emission-reduction and market more requires the overall situation reduced costs at home, energy saving evaluates the indispensable key factor of of injection machine ability.
In sum, target of the present invention is for the management of separate unit injection-moulding device provides decision support, from the objective equipment complex ability evaluating injection machine all sidedly in product quality, equipment dependability and energy saving three aspects, and the capacity loss reason identified by the comprehensive analysis of overall equipment efficiency.comprehensive efficiency of equipment and equipment complex ability in production, thus provide decision support for the equipment control how improving plant efficiency and carry out science.
More than that better enforcement of the present invention is illustrated, but the invention is not limited to described embodiment, those of ordinary skill in the art also can make all equivalent variations or replacement under the prerequisite without prejudice to spirit of the present invention, and these equivalent distortion or replacement are all included in the application's claim limited range.
Claims (10)
1., based on the injection machine management decision method of equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment, it is characterized in that: comprising:
S1, to evaluate according to equipment dependability index, product quality indicator and the device energy conservation index equipment complex ability to injection machine;
S2, the overall equipment efficiency.comprehensive efficiency of equipment of injection machine to be evaluated, and build the two-dimentional decision matrix be made up of the equipment complex ability evaluated and overall equipment efficiency.comprehensive efficiency of equipment;
S3, identify capacity loss reason in production according to the two-dimentional decision matrix built, and carry out injection machine management decision according to the result identified.
2. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 1, it is characterized in that: described equipment dependability index is failure rate, described product quality indicator is Measure of Process Capability C
pk, described device energy conservation index is consumption rate.
3. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 2, it is characterized in that: described step S1, it comprises:
S11, determine the evaluation criterion of equipment dependability index, product quality indicator and device energy conservation index;
S12, determine the weight matrix of equipment dependability index, product quality indicator and device energy conservation index;
S13, determine the fuzzy evaluating matrix that is made up of degree of membership according to evaluation criterion;
S14, weight matrix to be multiplied with fuzzy evaluating matrix, to obtain grade evaluation matrix, and according to the equipment complex ability rating of grade evaluation matrix determination injection machine.
4. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 3, it is characterized in that: described step S12, it comprises:
S121, by expert to these three indexs of equipment dependability index, product quality indicator and device energy conservation index carry out tax weigh;
S122, utilization analytical hierarchy process are analyzed the result that expert composes power, finally draw the weight matrix W={0.45 of equipment dependability index, product quality indicator and device energy conservation index, 0.33,0.22}, wherein, 0.45 is the weight of equipment dependability index, and 0.33 is the weight of product quality indicator, and 0.22 is the weight of device energy conservation index.
5. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 4, it is characterized in that: described step S13, it comprises:
S131, set up evaluation points set and opinion rating set, the expression formula of described evaluation points set U and opinion rating set V is respectively:
U={u
i| i=1,2,3}={u
1, u
2, u
3, V={v
j| j=1,2,3}={v
1, v
2, v
3, wherein, u
1for failure rate, u
2for C
pk, u
3for consumption rate, v
1for height, v
2for in, v
3for low;
S132, set up different evaluation factor u
ito different evaluation grade v
jsubordinate function v
j(u
i);
S133, according to set up subordinate function v
j(u
i) obtaining the fuzzy evaluating matrix R that is made up of degree of membership, the expression formula of described fuzzy evaluating matrix R is:
6. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 5, is characterized in that:
The subordinate function v of described foundation
j(u
i) comprise failure rate u
1respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
1), v
2(u
1) and v
3(u
1), represent C
pku
2respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
2), v
2(u
2) and v
3(u
2), consumption rate u
3respectively to opinion rating v
1, v
2and v
3subordinate function v
1(u
3), v
2(u
3) and v
3(u
3), described subordinate function v
1(u
1), v
2(u
1) and v
3(u
1) expression formula be:
Described subordinate function v
1(u
2), v
2(u
2) and v
3(u
2) expression formula be:
Described subordinate function v
1(u
3), v
2(u
3) and v
3(u
3) expression formula be:
7. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 5, it is characterized in that: described step S14, it comprises:
S141, be multiplied with fuzzy matrix R by weight matrix W, obtain grade evaluation matrix B, the expression formula of described grade evaluation matrix B is: B=WR=(b
1, b
2, b
3);
B in S142, comparison scale Evaluations matrix B
1, b
2and b
3the size of these three elements, and according to the equipment complex ability rating of the maximal value determination injection machine in these three elements.
8. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 7, it is characterized in that: described step S142, it is specially:
B in comparison scale Evaluations matrix B
1, b
2and b
3the size of these three elements, if the maximal value in these three elements is b
1, then the equipment complex ability rating of injection machine is high; If the maximal value in these three elements is b
2, then during the equipment complex ability rating of injection machine is; If the maximal value in these three elements is b
3, then the equipment complex ability rating of injection machine is low.
9. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 8, it is characterized in that: described step S2, it comprises:
S21, judge that whether the overall equipment efficiency.comprehensive efficiency of equipment of injection machine is higher than 85%, the grade of the overall equipment efficiency.comprehensive efficiency of equipment if so, then evaluated is for high, otherwise the grade of the overall equipment efficiency.comprehensive efficiency of equipment then evaluated is low;
S22, build the two-dimentional decision matrix be made up of the equipment complex ability evaluated and overall equipment efficiency.comprehensive efficiency of equipment.
10. the injection machine management decision method based on equipment complex ability and overall equipment efficiency.comprehensive efficiency of equipment according to claim 9, it is characterized in that: described step S3, it is specially:
Identify the capacity loss reason in production according to the concrete grade of equipment complex ability in two-dimentional decision matrix and overall equipment efficiency.comprehensive efficiency of equipment, and carry out injection machine management decision according to the result identified:
If the grade of equipment complex ability is low and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then alarm causes production efficiency low because of machine performance difference, and stops at once producing and carrying out machine performance improvement;
If the grade of equipment complex ability be in and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then check that the low reason of production efficiency is that the general or equipment of equipment complex performance occurs abnormal with other factor;
If the grade of equipment complex ability is high and the grade of overall equipment efficiency.comprehensive efficiency of equipment is low, then alarm machine is functional but cause production efficiency low because equipment there are serious problems with other factor;
If the grade of equipment complex ability is low and the grade of overall equipment efficiency.comprehensive efficiency of equipment is height, then alarm causes high cost because machine power consumption is excessive, is badly in need of the energy saving improving machine;
If the grade of equipment complex ability be in and the grade of overall equipment efficiency.comprehensive efficiency of equipment for high, then show that equipment is with other factor no problem, need to check whether emphatically that energy saving because of machine is abnormal and cause production efficiency low;
If the grade of equipment complex ability is high and the grade of overall equipment efficiency.comprehensive efficiency of equipment is height, then should maintain current state and proceed to produce.
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