CN109146286A - A kind of OEE ameliorative way based on TOC theory - Google Patents
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Abstract
The invention discloses a kind of OEE ameliorative way based on TOC theory, clear and intuitive OEE report is formed by calculated result, and analyzes the influence factor for causing OEE to lose.TOC basic theories has specifically been used to practice method with it, establish the OEE improvement model for being suitable for semiconductor assembly and test process, identifying influences the bottleneck device that OEE level is promoted in production process, calculate corresponding buffering capacity, and then complete the analysis and improvement to OEE.Compared with prior art, it this method provides a kind of practicable comprehensive improvement plan of OEE, is significantly risen so that the OEE level of bottleneck device has, overall efficiency is improved.And due to the optimization of bottleneck, the OEE level of most equipment has obtained certain promotion, and the production efficiency of system entirety is improved.
Description
Technical field
The present invention relates to the model foundation of industrial equipment capacity level and improvement, and in particular to one kind is managed based on TOC
The OEE ameliorative way of opinion.
Background technique
Under normal conditions, each equipment in production process has the maximum production capacity on its theory significance.However in reality
In the production of border, equipment can be because a variety of factors be shut down, the product for being perhaps unable to the operation of high-performance high standard or producing
Yield is not achieved absolutely, these factors have mechanical breakdown, cleaning to repair machine, material extension, product defects etc..In order to measure
Ratio of this actual production capacity of equipment relative to theoretical maximum production capacity, in order to play equipment maximum capacity and reduce production
In loss, overall equipment efficiency.comprehensive efficiency of equipment (OEE) is widely used as a kind of independent measuring tool.
Constraint theory (Theory of Constraints, TOC) is a set of based on rate of production and marketing, quantity in stock and operating cost
Index system, and gradually form a kind of management theory and solution for the purpose of increasing rate of production and marketing.Constraint theory is thought
In any system of enterprise, all in the presence of restricting the limiting factor that is normally carried out of production management activity, that is, so-called constraint or
Person's bottleneck (Constraints).The buffering capacity of accurate Calculation bottleneck resource is also the key step that TOC theory is used in business administration
Suddenly.
It is the concrete practice for applying to production plan and control that DBR (Drum-Buffer-Rope) system, which is TOC theory, main
Contain " drum (Drum) ", " buffer (Buffer) " and " rope (Rope) " three elements.In production management system,
Drum is the best rhythm point (drumbeat) controlled in whole process, is the key that guarantee system rate of production and marketing, the bottleneck in system is just
Speed of production can be controlled as drumbeat, bottleneck.From the angle of production plan and control, Drum is mainly responsible for abundant digging
The Potential performance of bottleneck is dug, and formulates production plan on the basis of bottleneck.Buffer as a kind of buffer protection mechanism,
Purpose is to protect the production operation of bottleneck not by the movable interference of other productions and influence, and prevents enchancement factor from causing bottle
The fluctuation of neck, to improve the effective output of system.Rope is bottleneck and the tie that upstream link is linked up, and non-bottleneck is allowed to provide
The rhythm of production in source is followed by bottleneck, to keep the equilibrium of production logistics, completes yielding to for bottleneck.The OEE index of equipment
It is the object that enterprise pays close attention to, but OEE only measures single device production capacity at present, and not specifically using constraint reason
It is optimized by OEE.Furthermore the computational problem of bottleneck identification strategy and buffer model lacks reasonable effective solution approach, because
This needs a kind of comprehensive improvement plan of practicable OEE.
Summary of the invention
Goal of the invention: in order to overcome defect existing in the prior art, the present invention provides a kind of OEE based on TOC theory
Ameliorative way.This method reasonable effective solution computational problem of bottleneck identification strategy and buffer model, and it is practicable
Realize the comprehensive improvement plan of OEE.
Technical solution: a kind of OEE ameliorative way based on TOC theory of the present invention includes the following steps:
(1) OEE computation model: the OEE=time rate of starting × Performance Rate × accepted product percentage is established；
(2) acquisition obtains parameters in OEE computation model；
(3) according to OEE computation model and analytical technology, the report of generating device efficiency situation；
(4) analytical statement obtains the concrete reason of OEE loss；
(5) building bottleneck device identification, finds weakest link in production system；
(6) settling time buffer model and calculate the time buffering；
(7) establishing OEE according to above step improves system, and improves system using OEE and change to the OEE of production process
It is kind.
Specifically, in the OEE computation model of the step (1):
The time rate of starting=running time/duration of load application；
Performance Rate=processing quantity × theory process-cycle/running time；
Accepted product percentage=qualified product quantity/processing quantity.
In the step (2), acquisition obtain OEE computation model in parameters when, be by maintenance data REPOSITORY TECHNOLOGY,
Initial data is collected, after being read out, handle and converting, and then OEE is supplied to and calculates use.
In the step (3), report is showed by Echarts technology in service terminals system, the report
Content include overall OEE days tendency charts of all devices, the OEE day tendency chart of same type equipment, product yield day trend
Figure, time start rate day tendency chart, Performance Rate day tendency chart and device status information figure.
In the step (5), bottleneck device identification includes the following steps:
(5.1) common bottleneck effect index is subjected to Classifying Sum, by the correlation between analysis indexes, established
Rate, average active time, goods in process inventory, workpiece delivery date are started as more attributes of evaluation index using total load time, speed
Bottleneck identification model；
(5.2) overall merit is carried out to all properties: initially sets up multiattribute bottleneck identification matrix, the identification is asked
Topic is converted into Multiple Attribute Decision Problems；Then identification calculating is carried out using TOPSIS method, by construct ideal bottleneck device and
Ideal non-bottleneck device, analysis all devices and they close to degree, so that it is final to identify to carry out the overall merit of equipment
Bottleneck.
In the step (6), settling time buffer model and calculate the time buffering the step of include:
(6.1) settling time buffer model: the different type for upstream process is needed to determine that buffer time measures；
(6.2) equipment state is analyzed based on Markov process, reasoning can obtain the Steady temperature field of equipmentWherein, f is the failure rate of equipment, and m is the repair rate of equipment；
(6.3) the time buffering of different process types is calculated.
The utility model has the advantages that the present invention forms clear and intuitive OEE report by calculated result, and analyzes and OEE is caused to lose
Influence factor.It has specifically used TOC basic theories to practice method with it, has established and be suitable for semiconductor assembly and test process
OEE improves model, and identifying influences the bottleneck device that OEE level is promoted in production process, calculates corresponding buffering capacity, and then complete
Analysis and improvement to OEE.Compared with prior art, this method provides a kind of practicable comprehensive improvement plan of OEE, make
The OEE level for obtaining bottleneck device, which has, to be significantly risen, and overall efficiency is improved.And it is most of due to the optimization of bottleneck
The OEE level of equipment has obtained certain promotion, and the production efficiency of system entirety is improved.
Detailed description of the invention
Fig. 1 is a kind of flow chart of OEE ameliorative way based on TOC theory；
Fig. 2 is the ETL structural schematic diagram of OEE management module；
Fig. 3 is the bottleneck identification flow chart based on TOPSIS method；
Fig. 4 is system OEE days tendency chart in embodiment；
Fig. 5 is the tendency chart of equipment OEE days of certain in embodiment 6；
Fig. 6 is OEE days tendency charts of certain equipment in embodiment；
Fig. 7 is equipment running status figure in embodiment；
Fig. 8 is the OEE comparative result figure that bottleneck device improves front and back in embodiment.
Specific embodiment
In the following, being described in further details in conjunction with the accompanying drawings and embodiments to the present invention.
As shown in Figure 1, a kind of OEE ameliorative way based on TOC theory, this method comprises the following steps:
(1) OEE computation model: the OEE=time rate of starting × Performance Rate × accepted product percentage is established；Wherein, equipment
The time rate of starting is the ratio of equipment actual production time and planned production time, i.e.,；The time rate of starting=running time/load
Time.The Performance Rate of equipment is that speed starts rate and starts the product of rate only,After reduction of a fraction:
Performance Rate=processing quantity × theory process-cycle/running time.Accepted product percentage is qualified product quantity and adds
The ratio of number amount, i.e. accepted product percentage=qualified product quantity/processing quantity.Therefore, it can be deduced that OEE last calculation formula
Are as follows:
(2) acquisition automated obtains parameters in OEE computation model: as shown in Fig. 2, data a part is from enterprise
It is extracted in the database of existing system (such as YMS, MES), another part is directly grabbed from device systems, mainly equipment shape
The state time.The former needs to contact with Database, and the latter then needs to obtain device data by SECS/GEM communication protocol.It is logical
The event report that standing preparation gives host is only defaulted, the data not necessarily really needed comprising host.The present invention takes
The mode for redefining event report obtains the event report of specified parameter, and the SVID of required parameter is encapsulated into specified CEID and is marked
In the event report of knowledge.It after being collected into initial data, needs to be read out, handle and convert, and then be supplied to OEE calculating to make
With this has used ETL, i.e. data warehouse technology.
(3) according to OEE computation model and analytical technology, the report of generating device efficiency situation；It will by way of report
Device efficiency situation is specifically shown.Report form showing function is carried out in service terminals system by Echarts technology real
It is existing.System background calculates related data in OEE database according to standard OEE calculation formula, while utilizing Echarts work
Tool draws OEE report.User with the OEE data of query facility and can check related statements by browser interface, including all
Overall OEE days tendency charts of equipment, the OEE day tendency chart of same type equipment, product yield day tendency chart, time start rate day
Tendency chart, Performance Rate day tendency chart and device status information figure.
(4) analytical statement obtains the concrete reason of OEE loss；As shown in figure 4, OEE on the 7th is horizontal in certain production instance
It is lower, it chooses wherein 6 equipment and is analyzed.It is its OEE days tendency chart shown in referring to figure 5..It can be seen that one therein
Equipment day OEE level is lower.Fig. 6 is equipment day tendency chart.The horizontal one day minimum equipment state of its OEE can be found,
Such as Fig. 7, it is exactly that unplanned time internal fault shutdown and maintenance take long time that the equipment time on the same day, which starts the too low factor of rate, sternly
Equipment production is affected again.
(5) step as shown in Figure 3 is pressed, weakest link in production system is found in building bottleneck device identification；Specifically,
Including following process:
(5.1) common bottleneck effect index is subjected to Classifying Sum, by the correlation between analysis indexes, established
Multiattribute bottleneck identification model.From the angle of mechanical floor, total load time, speed start rate, average active time, processing etc.
It is evaluation index to the time.From the angle of workpiece layer, goods in process inventory, workpiece delivery date, workpiece cost are evaluation indexes.According to
Reflect three indexs of capacity of equipment --- total load time, speed start rate and average active time, final choice establish with
Total load time, speed start rate, average active time, goods in process inventory, more attribute bottles that workpiece delivery date is evaluation index
Neck identification model；As shown in table 1 it is the data statistics of 10 equipment:
1 bottleneck identification achievement data of table statistics
(5.2) overall merit is carried out to all properties: initially sets up multiattribute bottleneck identification matrix, the identification is asked
Topic is converted into Multiple Attribute Decision Problems；Then identification calculating is carried out using TOPSIS method, by construct ideal bottleneck device and
Ideal non-bottleneck device, analysis all devices and they close to degree, so that it is final to identify to carry out the overall merit of equipment
Bottleneck.Specifically, including the following steps:
(5.2.1) establishes the evaluation decision matrix of bottleneck identification, it is assumed that equipment integrates as M={ M1,M2,…,Mm, evaluation belongs to
Property integrates as N={ N1,N2,…,Nn, MiIndicate i-th equipment, NjIndicate jth item evaluation index；Building identification and evaluation matrix A=
(aij)m×n, wherein i=1,2 ... m, j=1,2 ... n.By indices data conversion in table 1 at bottleneck identification evaluations matrix,
That is input matrix.
(5.2.2) is standardized evaluations matrix using vector standardized method, obtains standardization evaluations matrix R=
(rij)m×n；Rate, average active time and goods in process inventory are started for the total load time in model, speed and belong to determine more
Profit evaluation model index in plan model, normalizing are as follows:
Workpiece delivery date index in model, belongs to cost type index, normalizing are as follows:
(5.2.3) determines the weight of each evaluation index: five indices are metered dose index, index in bottleneck identification model
Specific data can be from directly acquiring in equipment or obtaining indirectly from the production management system of enterprise, then using suitable
Assign the weight that power evaluation method calculates each index.In the present embodiment, the weight of distinguishing indexes is calculated based on entropy assessment.It is weighed
Weight vector W=(ω1,ω2,…,ωn).According to the calculating process of above-mentioned entropy assessment, the weighted value of five indices is obtained, respectively
0.2681,0.0074,0.3785,0.2018,0.1442.
(5.2.4) establishes the weighting evaluation matrix of bottleneck identification；On the basis of weight vectors W and standardization evaluations matrix R
On, calculate weighted normal evaluations matrix E=(eij)m×n, formula are as follows:
E=(eij)m×n=(ωj·rij)m×n
(5.2.5) determines the ideal bottleneck device e under each bottleneck identification index j+With ideal non-bottleneck device e-；
(5.2.6) calculates every equipment to ideal bottleneck device e+DistanceAnd arrive ideal non-bottleneck device e-'s
Distance
(5.2.7) calculates the approach degree C of every equipment and optimal bottleneck devicei(i=0,1 ... m), by CiAll values carry out
Sequence, CiBeing worth maximum equipment is exactly bottleneck device；Wherein:
Solve to obtain approach degree of 10 equipment relative to optimal bottleneck device in table 1 according to above-mentioned steps, respectively
0.4166,0.8177,0.4351,0.6504,0.8265,0.4579,0.2294,0.5331,0.0466,0.8220.Therefore,
In the 5th equipment be bottleneck device.
(6) settling time buffer model and calculate the time buffering；Specifically, including the following steps:
(6.1) settling time buffer model: in advance release time of the time buffering for the setting material in production process,
Upstream process is weakened because of fluctuation brought by the factors such as failure, to avoid bottleneck device from being in idle state, to ensure
The continuous and stabilization of rhythm of production；The different type for upstream process is needed to determine that buffer time measures；
(6.2) equipment state is analyzed based on Markov process, it is assumed that equipment is in chance failure period, does not reach
To service life, then failure rate and repair rate are bordering on constant as the time increases, and the failure rate of equipment is denoted as f, repair rate note
For m.Reasoning can obtain the Steady temperature field of equipment
(6.3) the time buffering of different process types is calculated.The time between failures of equipment in one cycle, referred to as
Average Inactivity Interval, i.e. MTBF (Mean Time Between Failure).Equipment because downtime be in reparation state when
Between be known as mean repair time, i.e. MTTR (Mean Time To Repair), sum of the two be a duty cycle.By upper
The calculating to equipment transient availability is stated, effective time and out-of-service time in machine cycle can be extrapolated.It connects
Get off to discuss the setting of buffering capacity respectively according to the type of bottleneck device upstream process.Specifically,
(6.3.1) when the upstream process of a bottleneck device only equipment, upstream equipment will cause bottleneck because of disorderly closedown
Equipment is under feeding, causes it that can not produce, it is therefore assumed that the speed of production of the normal condiments of equipment is invariable, need to only guarantee on
It swims effective operation time (MTBF) of the equipment within buffer time and is higher than its malfunction and failure time (MTTR) within the duty cycle,
Bottleneck device can be met to be not affected；It is assumed that the failure rate of upstream equipment is f, repair rate m, duty cycle TL, finally
Obtain the calculation formula of buffer time:
(6.3.2) when bottleneck device upstream process multiple devices series connection when, one device fails of any of them, all
Will lead to production operation can not continue, and bottleneck device will be forced to stop work, therefore upstream link all devices are within buffer time
The sum of effective operation time needs to be higher than malfunction and failure time the sum of of all devices within the duty cycle；It is assumed that upstream process is set
Standby sum is n, and the failure rate of a certain equipment is fi, repair rate mi, duty cycle TLi, corresponding buffer time is TBi,
Transient availability is replaced used here as the Steady temperature field of equipment, then the calculation formula that may finally be buffered the time:
When (6.3.3) bottleneck device reentries upstream process, same equipment may repeatedly participate in the production operation of a batch,
Then the setting of buffer time needs the variability of influence factor and buffering in view of bottleneck device itself.By to series connection work
The calculating of sequence time buffering, time buffering each time is obtained according to the processing characteristics of upstream all devices, due to slow
The fluctuation that device solves upstream link is rushed, next time equipment of the buffering it is not necessary that buffering is obtained before considering further that, therefore slow
The zequin for rushing the time is the buffer of raw material or last time, according to the above analysis, using time buffer as cut-point,
The processing flow of entire batch is divided into multi-stage series sub-process, the buffering of time required for each sub-process individually calculates
Amount；If in sub-process including bottleneck device, the failure rate, repair rate and process-cycle of bottleneck device itself are substituted into meter
It calculates；Assuming that bottleneck device is reentried x times in a certain production batch, then whole flow process is resolved into x+1 sub-process, needed simultaneously
X time buffering is calculated, the buffering capacity of each sub-process is denoted as Ti, wherein i=1,2 ... x；According to the concatenated buffering of more equipment
Calculation formula can obtain:
N in formulaiIndicate the equipment sum of i-th of sub-process；
Due to the presence of processing flow is multiple entering property, time buffering capacity of the bottleneck device under different processes is to be not fixed
, it is related to the processing characteristics of upstream portion neighbouring device.If the time buffers the mode for being arranged to dynamic change by process, real
It is difficult now to get up, and therefore, the maximum value of sub-process buffering capacity is taken to buffer T as the final time of bottleneck deviceB；
TB=max { T1,T2,…Ti}
The buffer time amount that the bottleneck device setting of example from above can be calculated according to this formula is 16.2h.
(7) according to above step, establishing OEE in actual production improves system, and improves system to producing using OEE
The OEE of journey is improved.It is obviously improved as shown in figure 8, being had using the OEE level of this method equipment.
Claims (9)
1. a kind of OEE ameliorative way based on TOC theory, which comprises the steps of:
(1) OEE computation model: the OEE=time rate of starting × Performance Rate × accepted product percentage is established；
(2) acquisition obtains parameters in OEE computation model；
(3) according to OEE computation model and analytical technology, the report of generating device efficiency situation；
(4) analytical statement obtains the concrete reason of OEE loss；
(5) building bottleneck device identification, finds weakest link in production system；
(6) settling time buffer model and calculate the time buffering；
(7) establishing OEE according to above step improves system, and is improved using OEE improvement system to the OEE of production process.
2. the OEE ameliorative way according to claim 1 based on TOC theory, which is characterized in that in the step (1),
The time rate of starting=running time/duration of load application；
Performance Rate=processing quantity × theory process-cycle/running time；
Accepted product percentage=qualified product quantity/processing quantity.
3. the OEE ameliorative way according to claim 1 based on TOC theory, which is characterized in that the step (2) is fortune
With data warehouse technology, initial data is collected, after being read out, handle and converting, OEE is supplied to and calculates use.
4. the OEE ameliorative way according to claim 1 based on TOC theory, which is characterized in that lead in the step (3)
It crosses Echarts technology to show report, the content of the report includes the overall OEE days tendency charts, same of all devices
The OEE day tendency chart of type equipment, product yield day tendency chart, time start rate day tendency chart, Performance Rate day tendency chart
And device status information figure.
5. the OEE ameliorative way according to claim 1 based on TOC theory, which is characterized in that in the step (5), bottle
The identification of neck equipment includes the following steps:
(5.1) common bottleneck effect index is subjected to Classifying Sum, by the correlation between analysis indexes, established with total
Duration of load application, speed start rate, average active time, goods in process inventory, more attribute bottlenecks that workpiece delivery date is evaluation index
Identification model；
(5.2) overall merit is carried out to all properties: initially sets up multiattribute bottleneck identification matrix, the identification problem is turned
Turn to Multiple Attribute Decision Problems；Then identification calculating is carried out using TOPSIS method, by constructing ideal bottleneck device and ideal
Non- bottleneck device, analysis all devices and they close to degree, to carry out the overall merit of equipment to identify final bottle
Neck.
6. the OEE ameliorative way according to claim 5 based on TOC theory, which is characterized in that in the step (5.2),
Overall merit is carried out to all properties to include the following steps:
(5.2.1) establishes the evaluation decision matrix of bottleneck identification, it is assumed that equipment integrates as M={ M1,M2,…,Mm, evaluation attributes collection
For N={ N1,N2,…,Nn, MiIndicate i-th equipment, NjIndicate jth item evaluation index；Building identification and evaluation matrix A=
(aij)m×n, wherein i=1,2 ... m, j=1,2 ... n；
(5.2.2) is standardized evaluations matrix using vector standardized method, obtains standardization evaluations matrix R=(rij)m×n；It is right
Total load time in model, speed start rate, average active time and goods in process inventory and belong in more decision models
Profit evaluation model index, normalizing are as follows:
Workpiece delivery date index in model, belongs to cost type index, normalizing are as follows:
(5.2.3) determines the weight of each evaluation index: using the weight weighed evaluation method and calculate each index is assigned, obtaining weight vectors
W=(ω1,ω2,…,ωn)；
(5.2.4) establishes the weighting evaluation matrix of bottleneck identification；On the basis of weight vectors W and standardization evaluations matrix R, meter
Calculate weighted normal evaluations matrix E=(eij)m×n, formula are as follows:
E=(eij)m×n=(ωj·rij)m×n
(5.2.5) determines the ideal bottleneck device e under each bottleneck identification index j+With ideal non-bottleneck device e-；
(5.2.6) calculates every equipment to ideal bottleneck device e+DistanceAnd arrive ideal non-bottleneck device e-Distance
(5.2.7) calculates the approach degree C of every equipment and optimal bottleneck devicei(i=0,1 ... m), by CiAll values are arranged
Sequence, CiBeing worth maximum equipment is exactly bottleneck device；Wherein:
7. the OEE ameliorative way according to claim 6 based on TOC theory, which is characterized in that the step (5.2.3)
In the weight of each evaluation index is calculated based on entropy assessment.
8. the OEE ameliorative way according to claim 1 based on TOC theory, which is characterized in that in the step (6), build
Between immediately buffer model and calculate the time buffering the step of include:
(6.1) settling time buffer model: determine that buffer time measures for the different type of upstream process；
(6.2) equipment state is analyzed based on Markov process, reasoning can obtain the Steady temperature field of equipment
Wherein, f is the failure rate of equipment, and m is the repair rate of equipment；
(6.3) the time buffering of different process types is calculated.
9. the OEE ameliorative way according to claim 8 based on TOC theory, which is characterized in that in the step (6.3),
Calculate different process types time buffering the step of include:
(6.3.1) is when the upstream process of a bottleneck device only equipment, it is assumed that the failure rate of upstream equipment is f, and repair rate is
M, duty cycle TL, finally obtain the calculation formula of buffer time:
(6.3.2) when bottleneck device upstream process multiple devices series connection when, it is assumed that upstream process equipment sum be n, a certain
The failure rate of equipment is fi, repair rate mi, duty cycle TLi, corresponding buffer time is TBi, used here as the steady of equipment
State availability replaces transient availability, then the calculation formula that may finally be buffered the time:
(6.3.3) is when bottleneck device reentries upstream process, it is assumed that in a certain production batch, bottleneck device is reentried x times, then will be whole
A flowsheet simulation needs to calculate x time buffering at x+1 sub-process, and the buffering capacity of each sub-process is denoted as Ti, wherein
I=1,2 ... x；If in sub-process including bottleneck device, by the failure rate of bottleneck device itself, repair rate and processing week
Phase, which substitutes into, to be calculated；According to the concatenated buffering calculation formula of more equipment, can obtain:
N in formulaiIndicate the equipment sum of i-th of sub-process；
The maximum value of sub-process buffering capacity is taken to buffer T as the final time of bottleneck deviceB；
TB=max { T1,T2,…Ti}。
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