CN106469351A - A kind of filling and package production line efficiency loss analysiss method - Google Patents
A kind of filling and package production line efficiency loss analysiss method Download PDFInfo
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- CN106469351A CN106469351A CN201610796702.4A CN201610796702A CN106469351A CN 106469351 A CN106469351 A CN 106469351A CN 201610796702 A CN201610796702 A CN 201610796702A CN 106469351 A CN106469351 A CN 106469351A
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q50/00—Systems or methods specially adapted for specific business sectors, e.g. utilities or tourism
- G06Q50/04—Manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/80—Management or planning
Abstract
The invention provides a kind of filling and package production line efficiency loss analysiss method, methods described includes:Data mart modeling;To loss classification;Calculate all kinds of losses;Draw total losses;The present invention is effectively assessed by losses all kinds of to filling and package production line, accurately analyzed with quantification manner, the every loss distribution situation in detailed description package production, lose internal major influence factors with every class, profound items of excavating are lost simultaneously, and targetedly solve problem, improve production efficiency.
Description
Technical field
The present invention relates to a kind of production line efficiency loss analysiss method, in particular to a kind of filling and package production line efficiency
Loss analysiss method.
Background technology
At present, most domestic filling and package production line includes being connected by conveying transmission belt, is run by motor cooperation
A series of keys such as unpiler, bottle washer, empty bottle verifier, wine filling machine, full bottle verifier, sterilization machine, labelling machine and recrater
Equipment.
Packaging production line lies substantially in the extensive management mode of comparison, lacks digitized systematic analysiss, and entirely
The systematization analysis of production line degree of cooperation, very difficult quantitative analysiss go out the maximum link of problem, Yi Jiying in whole production process
Ring the factor of whole production line efficiency it is impossible to weigh the whole efficiency of filling production lines.
In the increasingly fierce market competition, manufacturing enterprise in order to be in more favourable position in the market competition, to carry
The means such as high product quality, reduction production cost, to lift competitiveness it is ensured that number one, realize bigizationner of interests.Existing
Production line on remove outside advanced production equipment, lead to production cost increase factor also have:For the damage in production line
Analysis of losing points typically is provided only with product counting detection means and the counting assembly for counting bad products number, and only statistical product is qualified
Rate, have ignored the generation of shutdown event in flow production line.
Therefore, for realizing loss in efficiency in the analysis production line of clear and rational, not only want the qualified of statistical analysiss product
Rate, it is also contemplated that the generation of shutdown event, shutdown, the shutdown that official holiday leads to or preventative dimension that such as mechanical breakdown leads to
Repair shutdown leading to etc..
For solving the difficult problem that prior art runs into, in the urgent need to loss in efficiency analysis method in a kind of production line, to realize
Loss in efficiency in comprehensive system analysis production line.
Content of the invention
In order to solve the above-mentioned deficiency in the presence of prior art, the present invention provides a kind of filling and package production line efficiency to damage
Lose analysis method, methods described includes:
I, data mart modeling;
II, to loss classification;
III, all kinds of losses of calculating;
IV, draw total losses.
Preferably, the data of described step I datum processing includes:Teams and groups' information of yield record, the date, the overall time,
Fault time, wine filling machine yield, warehouse-in yield and normal speed, teams and groups' information of outage record, the time started, the end time,
Shut down big class, shut down classification, fault board and failure cause.
Preferably, the loss of step II includes:Shutdown loss, equipment fault loss and the qualified loss of product;
Described shutdown loss includes:No filling time, no fill loss, planned shut-down loss, external cause loss;
The equipment fault of described equipment fault loss includes:Mechanical breakdown, electric fault and speed slow down.
Preferably, the described no filling time includes:Official holiday and no order;
The planned shut-down of described planned shut-down loss includes:Preventative maintenance, technique cleaning, foam cleaning and startup stop
Machine;
Described external cause loss includes trans-departmental cooperation and goes wrong.
Preferably, described mechanical breakdown and electric fault include respectively:Unpiler, bottle washer, empty bottle verifier, transmission
Band, wine filling machine, full bottle verifier, sterilization machine, labelling machine, recrater, cartoning sealing machine and/or stacking machine break down.
Preferably, described bottle washer includes the reason breaking down:Bottle washer import card bottle;
The reason described filling machine breaks down includes:Wine tank changes broken in tank failure, wine filling machine entrance card bottle and wine filling machine
Bottle;
The reason described labelling machine breaks down includes:Labelling machine positioning adjusts unsuccessfully.
Preferably, each loss of described step III includes:
Speed loss SPL following formula calculates:
SPL=((LS* (TT NPT SDT ECT FT) MOT)/LS*TT) * 100% (1)
In formula, LS:The theoretical velocity of how many bottles per minute, TT:Total duration in units of minute, MOT:Wine filling machine is real
Border yield, NPT:The no packaging time in units of minute, SDT:Scheduled Down Time in units of minute, ECT:With minute
For the external cause time of unit, FT:The failure cause time in units of minute;
The loss BQL of substandard product is shown below:
BQL=((MOT OT)/LS*TT) * 100% (2)
In formula, LS:The theoretical velocity of how many bottles per minute, TT:Total duration in units of minute, MOT:Wine filling machine is real
Border yield, OT:Warehouse-in yield;
Described external cause loss ECL is shown below:
ECL=((BWT+ULT+LGT+QLT)/TT) * 100% (3)
In formula, BWT:Brewing Department in units of minute causes downtime, ULT:Public work in units of minute
The downtime causing, LGT:The downtime that Logistics Department in units of minute causes, QLT:Accessory in units of minute
The downtime that quality problems cause, TT:Total duration in units of minute.
Preferably, described step IV total losses Y following formula calculates:
Y=SPL+BQL+ECL (5)
In formula, SPL:Speed loss, BQL:The loss of substandard product, ECL:External cause loses.
Compared with immediate prior art, the technical scheme that the present invention provides has following excellent effect:
The technical scheme that the present invention provides accurately is analyzed with quantification manner, each in detailed description package production
Item loss distribution situation, and the internal major influence factors of every class loss, the every loss of profound level excavation simultaneously simultaneously targetedly solves
Certainly problem, improves production efficiency.
Brief description
Fig. 1 canned packaging production line loss in efficiency analysis principle structure chart of the present invention.
Specific embodiment
For a better understanding of the present invention, with reference to Figure of description and example, present disclosure is done further
Explanation.
The present invention provides a kind of filling and package production line efficiency loss analysiss method, specifically adopts five layers of losses in efficiency analysis
Method, methods described includes:
I, data mart modeling;
Data acquisition in data mart modeling is specially:Collection yield record and outage record essential information;
Choose a board as key machine.Based on Design of Production Line principle, it is crucial that we can analyze out this
Equipment is often referred to filling machine, and canning line performance mainly to be weighed by this machine.The yield of wine filling machine determines whole piece producing line
Yield.Every other board all will be fast than this board speed in theory.
Yield record and outage record essential information belong to the ground floor in five layers of loss in efficiency analytic process, yield record base
This packet information containing teams and groups, date, overall time, fault time, wine filling machine yield, warehouse-in yield, normal speed.Shut down note
Record essential information comprises teams and groups' information, opening time, downtime, shuts down duration, shut down big class, shut down classification, fault board
And failure cause.These information can reflect that cooperation ability between the integrated management ability of enterprise, department, equipment run
Ability and troubleshooting capability.Wherein initial time and termination time are all with key equipment for standard acquisition data.Administrative man
Member can consult the shutdown letter of the different dimensions such as certain time period, certain teams and groups, certain board, certain shutdown classification by ground floor
Breath.
II, to loss classification:
Shut down big class loss analysiss:Belong to the second layer in five layers of loss in efficiency analytic process, analyze each big class loss, point
Class defines project for no filling time, Scheduled Down Time, external cause time, fault time, speed loss percentage ratio, product
Certified products percent loss, shutdown collect duration.With beer glass bottle filling production lines QB/T 1,080 2007 and national security
Supervision general bureau formulates《Beer producers safety in production standardization evaluation criteria》It is foundation, by outage record essential information institute
Stating " shutdown big class " concrete class definition is no filling time, Scheduled Down Time, external cause time, fault time.Described
" speed loss percentage ratio "=(wine filling machine board yield/(overall time failure time))/normal speed;It is described that " product is qualified
Percent loss "=(wine filling machine board yield finally puts yield in storage)/wine filling machine board yield;Described " shutdown collects duration "
(time started end time) sum equal to all outage records of described outage record essential information;Production management personnel can
With the preliminary mainly general factor identifying that this producing line causing trouble occurs.Different shutdown big class according to sky granularity, all granularities,
Or moon granularity carries out converging this result of acquisition.Except temporal loss, in the range of normal working hourss, also there is speed
Loss and mass loss.The speed of whole piece producing line depends on the speed of wine filling machine, and mass loss mostlys come from wine filling machine and fills wine
Total output is to that section of loss of final warehouse-in.The loss of all categories causes the reduction of yield on filling and package production line,
The rising of cost and the loss of profit.
Shut down Classification Loss analysis:Belong to the third layer in five layers of loss in efficiency analytic process, analyze each Classification Loss, tool
The content that body is related to is relatively more, and class definition project is official holiday, no order, preventative maintenance, technique cleaning, foam is clear
Wash, start shutdown, Brewing Department, public work, Logistics Department, purchasing department, mechanical breakdown, electric fault.Production management personnel are
On the basis of two layers, locking is the efficiency which kind of classification factor have impact on producing line further." no filling time " described in the second layer
Shut down Classification Loss to analyze as official holiday, no order;" Scheduled Down Time " described in the second layer is shut down Classification Loss and is analyzed
Preventative maintenance, technique cleaning (CIP), foam cleaning, thread-changing, startup are shut down;" external cause time " described in the second layer shuts down
Classification Loss analysis is mainly trans-departmental cooperation and is specifically divided into Brewing Department, public work, Logistics Department, purchasing department, quality (outside);
" failure cause time " described in the second layer shuts down Classification Loss and analyzes as mechanical breakdown, electric fault.
Fault board loss analysiss:Belong to the 4th layer in five layers of loss in efficiency analytic process, in this layer analysis production line
All boards are to wine filling machine effect.Being specifically defined item is all boards and prevailing transmission band in producing line.According to third layer
Described " mechanical breakdown " and " electric fault ", each item specifically comprises following content:Unpiler, bottle washer, empty bottle verifier, biography
Defeated band, wine filling machine, full bottle verifier, sterilization machine, labelling machine, recrater, cartoning sealing machine and stacking machine.Production management personnel are the 3rd
More detailed that board analyzing problem maximum in whole producing line on the basis of layer, be relatively close to finds board reason.
Failure cause loss analysiss:Belong to the layer 5 in five layers of loss in efficiency analytic process, this layer is very careful must to be analyzed
Production line institute faulty to wine filling machine effect.This patent only simply lists some common failure causes, actual
On in whole producing line, be very many reason fault, need specifically constantly to arrange and analyze.For example:Bottle washer import
Broken bottle etc. in card bottle, conveyer belt card bottle, wine filling machine entrance card bottle, labelling machine positioning adjustment and wine filling machine.By this layer of production pipe
Reason personnel are eventually finding the immediate cause of impact producing line.As long as in routine duties constantly go solve major failure so that it may
Efficiency with the whole producing line of lifting slowly.It is finally reached the effect improving this core index of yield.Can certainly improve
Profit, reduces cost, finally perfectly realize filling and package production line digital management.
III, all kinds of losses of calculating
From the angle of asset utilization ratio, and with sky for loss analysiss sample, daily total duration 1440 minutes, with damaging
The mistake time obtains intraday loss rate divided by one day total duration.
Production efficiency:OAE=(OT/TT*LS) * 100%
Wherein OT represents warehouse-in yield (bottle), and TT represents total duration (minute), and LS represents producing line speed (bottle/minute).
No packaging loss:NPL=((NOT+PHT)/TT) * 100%
NOT represents no order holding time, and PHT represents the public holidays time, and TT represents total duration (minute)
Planned shut-down loses:SDL=((PMT+CIPWT+FWT+COT+SUT+ST)/TT) * 100%
Wherein PMT represents preventive maintenance time (minute), and CIPWT represents technique scavenging period (minute), and FWT represents bubble
Foam scavenging period (minute), COT represents conversion time (minute), and SUT represents starting time (minute), and ST represents dwell time
(minute), TT represents total duration (minute).
External cause loses:ECL=((BWT+ULT+LGT+QLT)/TT) * 100%
Wherein BWT represents Brewing Department and causes downtime (minute), ULT represent downtime that public work causes (point
Clock), LGT represents the downtime (minute) that Logistics Department causes, QLT represent downtime that fittings quality problem causes (point
Clock), TT represents total duration (minute).
Failure cause is lost:FL=((MCT+ECT+OPT)/TT) * 100%
Wherein MCT represents mechanical reason downtime (minute), and ECT represents electric reason downtime (minute), OPT generation
Table handling work reason downtime (minute), TT represents total duration (minute).
Speed loss:SPL=((LS* (TT NPT SDT ECT FT) MOT)/LS*TT) * 100%
Wherein LS representation theory speed (bottle/minute), TT represents total duration (minute), and MOT represents wine filling machine actual production,
NPT represents and no packs the time (minute), and SDT represents Scheduled Down Time (minute), and ECT represents the external cause time (minute),
FT representing fault reason time (minute).
Defective work loses:BQL=((MOT OT)/LS*TT) * 100%
Wherein LS representation theory speed (bottle/minute), TT represents total duration (minute), and MOT represents wine filling machine actual production
(bottle), OT represents warehouse-in yield (bottle).
From the angle of line hair productivity ratio, and with sky for loss analysiss sample, when daily projected operating times are total
Length deducts no fill planned time and special defects planned time, and special defects planned time refers to Scheduled Down Time.External cause
Lose as the external cause time divided by projected operating times, breakdown loss is fault time divided by projected operating times, speed damage
Lose difference for wine filling machine normal speed and average speed divided by normal speed, mass loss is that wine filling machine exports to whole section of warehouse-in and produces
Divided by wine filling machine total output, asset utilization ratio is warehouse-in yield divided by wine filling machine normal speed and plan for the defective work accumulation of line
The product of working time, is left the coordination loss that part is producing line.
IV, show that total losses Y following formula calculates:
Y=SPL+BQL+ECL (5)
In formula, SPL:Speed loss, BQL:The loss of substandard product, ECL:External cause loses.
These are only embodiments of the invention, be not limited to the present invention, all in the spirit and principles in the present invention
Within, any modification, equivalent substitution and improvement done etc., be all contained in applying for pending scope of the presently claimed invention it
Interior.
Claims (8)
1. a kind of filling and package production line efficiency loss analysiss method is it is characterised in that described analysis method includes:
I, data mart modeling;
II, to loss classification;
III, all kinds of losses of calculating;
IV, draw total losses.
2. filling and package production line efficiency loss analysiss method as claimed in claim 1 is it is characterised in that described step I number
Data according to processing includes:Teams and groups' information of yield record, date, overall time, fault time, wine filling machine yield, warehouse-in produce
Amount and normal speed, teams and groups' information of outage record, time started, end time, shutdown big class, shutdown classification, fault board
And failure cause.
3. filling and package production line efficiency loss analysiss method as claimed in claim 1 is it is characterised in that the loss of step II
Including:Shutdown loss, equipment fault loss and the qualified loss of product;
Described shutdown loss includes:No filling time, no fill loss, planned shut-down loss, external cause loss;
The equipment fault of described equipment fault loss includes:Mechanical breakdown, electric fault and speed slow down.
4. filling and package production line efficiency loss analysiss method as claimed in claim 3 is it is characterised in that during described no fill
Between include:Official holiday and no order;
The planned shut-down of described planned shut-down loss includes:Preventative maintenance, technique cleaning, foam cleaning and startup are shut down;
The external cause of described external cause loss includes trans-departmental cooperation and goes wrong.
5. filling and package production line efficiency loss analysiss method as claimed in claim 3 is it is characterised in that described mechanical breakdown
Include respectively with electric fault:Unpiler, bottle washer, empty bottle verifier, transmission belt, wine filling machine, full bottle verifier, sterilization machine,
Labelling machine, recrater, cartoning sealing machine and/or stacking machine break down.
6. filling and package production line efficiency loss analysiss method as claimed in claim 5 is it is characterised in that described bottle washer is sent out
The reason raw fault, includes:Bottle washer import card bottle;
The reason described filling machine breaks down includes:Wine tank changes broken bottle in tank failure, wine filling machine entrance card bottle and wine filling machine;
The reason described labelling machine breaks down includes:Labelling machine positioning adjusts unsuccessfully.
7. filling and package production line efficiency loss analysiss method as claimed in claim 1 is it is characterised in that described step III
Each loss include:
Speed loss SPL following formula calculates:
SPL=((LS* (TT NPT SDT ECT FT) MOT)/LS*TT) * 100% (1)
In formula, LS:The theoretical velocity of how many bottles per minute, TT:Total duration in units of minute, MOT:Wine filling machine is actual to produce
Amount, NPT:The no packaging time in units of minute, SDT:Scheduled Down Time in units of minute, ECT:With minute as list
The external cause time of position, FT:The failure cause time in units of minute;
The loss BQL of substandard product is shown below:
BQL=((MOT OT)/LS*TT) * 100% (2)
In formula, LS:The theoretical velocity of how many bottles per minute, TT:Total duration in units of minute, MOT:Wine filling machine is actual to produce
Amount, OT:Warehouse-in yield;
Described external cause loss ECL is shown below:
ECL=((BWT+ULT+LGT+QLT)/TT) * 100% (3)
In formula, BWT:Brewing Department in units of minute causes downtime, ULT:Public work in units of minute causes
Downtime, LGT:The downtime that Logistics Department in units of minute causes, QLT:Fittings quality in units of minute
The downtime that problem causes, TT:Total duration in units of minute.
8. filling and package production line efficiency loss analysiss method as claimed in claim 1 is it is characterised in that described step IV is total
Loss Y following formula calculates:
Y=SPL+BQL+ECL (5)
In formula, SPL:Speed loss, BQL:The loss of substandard product, ECL:External cause loses.
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CN107067188A (en) * | 2017-05-10 | 2017-08-18 | 北京泰清科技有限公司 | A kind of filling and package production line economic achievement evaluation method and system |
CN107146028A (en) * | 2017-05-10 | 2017-09-08 | 北京泰清科技有限公司 | A kind of filling and package production line carbon dioxide Energy Consumption Evaluation method and system |
CN108074047A (en) * | 2018-02-02 | 2018-05-25 | 南京水木自动化科技有限公司 | Made of metal tank product of production line quality calculation method and computing device |
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CN107146028A (en) * | 2017-05-10 | 2017-09-08 | 北京泰清科技有限公司 | A kind of filling and package production line carbon dioxide Energy Consumption Evaluation method and system |
CN107146028B (en) * | 2017-05-10 | 2021-02-23 | 南京水木自动化科技有限公司 | Carbon dioxide energy consumption evaluation method and system for filling and packaging production line |
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CN108573354B (en) * | 2018-04-28 | 2022-04-05 | 襄阳田园乐活米业有限公司 | Grain processing loss data analysis system and method |
CN108665176A (en) * | 2018-05-16 | 2018-10-16 | 武汉轻工大学 | Loss statistical method, device, system and storage medium based on paddy processing |
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CN111077863B (en) * | 2019-12-23 | 2020-09-29 | 深圳市安科讯电子制造有限公司 | Customized digital monitoring system |
CN115995122A (en) * | 2022-11-30 | 2023-04-21 | 歌尔股份有限公司 | Data processing method, production equipment, acquisition terminal, platform and system |
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