- Life-Cycle-Performance for Manufactures of Production Facilities - - - PowerPoint PPT Presentation

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- Life-Cycle-Performance for Manufactures of Production Facilities - - - PowerPoint PPT Presentation

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- Life-Cycle-Performance for Manufactures of Production Facilities - Prof. Dr.-Ing. Jrgen Fleischer, Dipl.-Ing. Jan Rhl, Dipl.-Wi.-Ing. Richard Ladenburger Zurich 27 August 2007 Zurich, 27 August 2007 Presentation of results of the research

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SLIDE 1
  • Life-Cycle-Performance for Manufactures of Production Facilities -
  • Prof. Dr.-Ing. Jürgen Fleischer, Dipl.-Ing. Jan Rühl, Dipl.-Wi.-Ing. Richard Ladenburger

Zurich 27 August 2007 Zurich, 27 August 2007

Presentation of results of the research project: LICMA.

LICMA is funded by the “Bundesministerium für Wirtschaft und Technologie”.

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SLIDE 2

Content

Initial Situation Objectives Approach Summary

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SLIDE 3

Content

Initial Situation Objectives Approach Summary

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SLIDE 4

Initial Situation

  • Industry Requirements -

Life-Cycle-Costs (LCC) for a time period of 10 years of a printing machine in use by the company MAN: the company MAN:

11,14 7,82 5,32 2,55 Staff Costs Acquisition Costs q Maintenance Costs Tool Costs Energy and Running Costs

Krawitz, Augsburg, 7.10.2004

Initial Situation:

56,15 17,02 Energy and Running Costs Other Costs

Initial Situation: Life-Cycle-Costs (LCC) are a main factor for the purchase decision. Every machine user is developing his own system of measurement of the LCC. High effort for the machine builder to calculate his proposition High effort for the machine builder to calculate his proposition. That´s why a standardization for the machine builder is necessary.

Initial Situation Objectives Approach Summary

a sta da d at o

  • t e

ac e bu de s ecessa y the base is development of a new approach for the machine user.

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SLIDE 5

Content

Initial Situation Objectives Approach Summary

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SLIDE 6

Objectives

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

Initial Situation Objectives Approach Summary

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SLIDE 7

Content

Initial Situation Objectives Approach Summary

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SLIDE 8

Approach

  • Ratio for measurement -

What is the main point in which a machine user is interested before his new purchase? new purchase? Unit Price Creating a new Index: LCP Approach for the machine builder:

∑

=

LC

Benefit LCP

Creating a new Index: LCP.

∑

=

LC

Costs LCP

Initial Situation Objectives Approach Summary

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SLIDE 9

Approach

  • Ratio for measurement -

To be able to calculate the unit price, we need p , Ratios of the production facility: LCP = Life-Cycle-Performance. OEE = Overall Equipment Effectiveness. LCC = Life-Cycle-Costs. Statistical Methods for the calculation of the OEE of machine components and the complete machine: Weibull-Analysis, FTA, FME(C)A, Quality-Simulation, … Methods for the calculation of LCC: VDI 2884, DIN 60300-3-2, VDMA 34160, … Data of the machine: Sources and fields of data for the determination of the LCP Index. , , ,

Initial Situation Objectives Approach Summary

Sources and fields of data for the determination of the LCP Index.

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SLIDE 10

Approach

  • Prognosis of LCP -

Availability

n) ) al) n n

*

MTBF, MTTR, …

Performance Rate

  • ls

… s … t (Person) st (Person ry ery

n

  • n

astructure astructure sts

  • sts

(Material) st (Materia

  • sts

Costs

  • dification
  • dification

*

Procedure, Organization, …

O ll E i t Quality Rate

nergy, Too ergy, Tools enance

  • Cost

ance -Cos Machine Machine

Installation

Installatio ngs and Infra and Infra Labor- Cos Labor -Co enance

  • Cost

ance -Cos Training

  • Co

raining -C

  • n and Mo

ion and M

Quality Problems, …

Overall Equipment Effectiveness (OEE)

En Ene Mainte Mainten Buildin Buildings Mainte Maintena T Tr Alterati Alterati

*

Initial-Costs

Initial- Costs

Operating

  • Costs

Operating-Costs Theoretical Output Unit Price Life-Cycle-Cost (LCC) Actual Output

Initial Situation Objectives Approach Summary

Unit Price

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SLIDE 11

Approach

  • Prognosis of LCP -

Estimation of the LCC Estimation of the benefit

) ) e e

l) l)

n n

Availability

*

ergy, Tools … nergy, Tools … ance-Cost ( Person) nance-Cost ( Person Macninery Macninery I nstallation I nstallation s and I nfastructure gs and I nfastructur Labour-Costs Labour-Costs

ance-Cost (Material ance-Cost (Materia

raining-Costs raining-Costs

  • n and Modification
  • n and Modification

Performance Rate

Quality Rate

* *

En En Maintena Mainten I

Initial-Costs Initial-Costs

Building Building

Operating-Costs Operating-Costs

L L

Maintena Maintena

Tr T Alteratio Alteratio

Overall Equipment Effectiveness (OEE) Theoretical Output

*

( )

  • duct
  • duct

l theoretica

OEE t Output Benefit

Pr Pr

∗ Δ =

∑ ∑

Life-Cycle- Cost Life-Cycle- Cost

[ ]

∑ ∑

=

d d d

Costs Costs

P

+

Actual Output

( )

  • duct
  • duct

LC

  • duct

l theoretica

p f

Pr Pr Pr

∑ ∑

  • duct

l theoretica

t Fi dC l Output

Pr

1 Δ ∗ =

∑ ∫

⎟ ⎞ ⎜ ⎛

[ ]

∑ ∑

LC g independin

  • duct

LC

Costs Costs

Pr

  • duct

l theoretica

FixedCycle

Pr

∑ ∫

⎟ ⎟ ⎠ ⎜ ⎜ ⎝ Δ

  • duct
  • duct

t depending

  • duct

dt t Costs

Pr Pr Pr

) (

t

dt t OEE OEE

  • duct

Pr

) ( =

∫

Δ

  • duct
  • duct

t OEE

Pr Pr

Δ =

Initial Situation Objectives Approach Summary

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SLIDE 12

Approach

  • Prognosis of LCP -

Life-Cycle-Cost Output (OEE)

Unit Price

∑ ∫ ∑

⎥ ⎥ ⎦ ⎤ ⎢ ⎢ ⎣ ⎡ ∗ dt t OEE FixedCycle Benefit ) ( 1

[ ]

∑ ∑ ∫ ∑ ∫ ∑ ∑

⎟ ⎟ ⎞ ⎜ ⎜ ⎛ + ⎥ ⎦ ⎢ ⎣ = =

Δ depending

  • duct

g independin

  • duct
  • duct
  • duct

t LC LC

dt t Costs Costs FixedCycle Costs f LCP

Pr Pr Pr Pr

) (

[ ]

∑ ∑ ∫

⎟ ⎠ ⎜ ⎝ Δ

LC

  • duct
  • duct

t depending

  • duct

g independin

  • duct

Pr Pr Pr Pr

) (

Initial Situation Objectives Approach Summary

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SLIDE 13

Approach

  • Prognosis of LCP -

OEE = Availability * Performance Rate * Quality Rate

Reliability Downtime Failures

Main considered aspects:

Data

N b f f il Running Breakdown Running MTBF Breakdown Running Number of failures MTTR

Failure Occurrence Resources are available

Failure Communication

Technician

  • n-site

Failure detected Repaired Starting

Initial Situation Objectives Approach Summary

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SLIDE 14

Approach

  • Prognosis of LCP -

Machine Structure Model Data Collection and Analysis Reliability Analysis Model and Analysis Analysis

Malfunction behavior (Weibull analysis) FMEA / Experts

Builder

After Sales Service p

Machine

Test & Simulation

M

Reliability

Spare part sales

ser

Parameters & Period of Repair

Maintenance Operating data

chine Us

Initial Situation Objectives Approach Summary

Maintenance data

Mac

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SLIDE 15

Approach

  • Perspective: Structured approach Condition Monitoring -

The two presented dimensions for the calculation of the unit price are:

Unit Price

Life-Cycle-Costs Productivity (OEE)

Goal: Model for prediction and controlling of the reliability and maintainability

  • f machines and plants over the Life-Cycle.

Life-Cycle-Costs Monitoring

Third Dimension:

Productivity (OEE)

Life-Cycle-

Life Cycle Costs Monitoring Productivity (OEE)

Life-Cycle- Performance Management

Initial Situation Objectives Approach Summary

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SLIDE 16

Approach

  • Perspective: Structured approach Condition Monitoring -

Life-Cycle-Performance Management: Reference model (3 ranks). y g ( )

MPM MPM MPM MPM Monitoring OEE OEE OEE P d ti it a

Felddaten- erfassung Ausw ertung Maßnahm en Review

OEE OEE OEE OEE

Felddaten- erfassung Ausw ertung Maßnahm en Review

Productivity LCC LCC LCC LCC Life - Cycle - Costs actual actua

Analysen KVP Controlling Synchr. Analysen KVP Controlling Synchr. Record I nter- pretation Actions Review

actual al

actu targe actual– target Markt, R&D MPM- Analyse Kunden- spez. Prognose Risiko- analyse Analysen KVP Controlling y Analysis

Am elioration

Controlling

Synchronize

actual– target

tar target

ual– et Markt, R&D Pflichten- heft Lasten- heft Risiko- analyse R&D Structural analysis

Custom er

requirem ents

Risk- anal sis

targe rget

Initial Situation Objectives Approach Summary

analysis

requirem ents

analysis

et

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SLIDE 17

Content

Initial Situation Objectives Approach Summary

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SLIDE 18

Summary

Ratio for measurement of performance

  • f production facilities:

Prognosis of Life-Cycle-Performance for the machine builder:

∑ ∑

=

LC

C Benefit LCP

  • f production facilities:

the machine builder:

∑

LC

Costs

e QualityRat eRate Performanc ty Availabili OEE ∗ ∗ =

Data collection for the prognosis of the Life-Cycle-Performance: Providing a structured approach for the machine builder:

MPM MPM MPM MPM

Felddaten- erfassung Ausw ertung Maßnahm en Review Analysen KVP Controlling Synchr.

Monitoring OEE OEE OEE OEE

Felddaten- erfassung Ausw ertung Maßnahm en Review

Productivity LCC LCC LCC LCC

Record I nter- pretation Actions Review

actuel Life-Cycle-Costs actuel actuel

act targ actuel – target A A B C D E B B 2 B 2.1 B 1 B 1.1 B 1.2 B 1.1.1 B 2.1.1 B 2.1.8

Reliability-Data-Model

Operating Data Maintenance Data Markt, R&D MPM- Analyse Kunden- spez. Prognose Risiko- analyse Markt, R& D Pflichten- heft Lasten- heft Risiko- analyse Analysen KVP Controlling Synchr. R&D Structural analysis Custom er requirem ents Risk- analysis Analysis Am elioration Controlling Synchronize target actuel – target target target tuel – rget After-Sales Service Dimensioning Spare Part Sales Expert-Extimation / FMEA Value-Analysis Test- & Simulation-Data Machine Manufacture Machine Tool Operator

Initial Situation Objectives Approach Summary

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SLIDE 19

Questions?

Thank you very much for your attention! for your attention!

  • Prof. Dr.-Ing. Jürgen Fleischer

Dipl.-Ing. Jan Rühl Dipl.-Wi.-Ing. Richard Ladenburger wbk Institute for Production Science University of Karlsruhe (TH)

  • Kaiserstr. 12 D-76128 Karlsruhe

Tel.: +49 (721) 608 4153 Fax: +49 (721) 699 153 a 9 ( ) 699 53 ladenburger@wbk.uka.de www.wbk-ka.de