设备整体效率OEE

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OEE（Overall Equipment Effectiveness），中文译为 “设备综合效率”，是衡量制造设备实际生产能力与理论最大产能之间比率的核心指标。
它被广泛应用于精益生产、TPM（全面生产维护）和智能制造中，用于识别生产损失、提升设备利用率和整体运营效率。



OEE（Overall Equipment Effectiveness）， The Chinese translation is "comprehensive efficiency of equipment", which is a core indicator for measuring the ratio between the actual production capacity of manufacturing equipment and the theoretical maximum production capacity.It is widely used in lean production, TPM (Total Productive Maintenance), and intelligent manufacturing to identify production losses, improve equipment utilization, and overall operational efficiency.

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OEE 的核心意义
✅ OEE = 时间开动率 × 性能开动率 × 合格品率

它将设备的全部损失归结为三大类，并通过一个单一的百分比数值（0% ~ 100%）直观反映设备的真实效率。

100% OEE：表示设备在计划生产时间内，以设计速度，持续生产出100%合格品——这是理想状态。
行业基准：
初级水平：< 60%
行业平均水平：60% ~ 75%
优秀水平：> 85%


The core significance of OEE
✅  OEE=Time activation rate x Performance activation rate x Qualified product rate

It categorizes all equipment losses into three main types and visually reflects the true efficiency of the equipment through a single percentage value (0%~100%).

100% OEE: Refers to the equipment continuously producing 100% qualified products at the design speed within the planned production time - this is the ideal state.
Industry benchmark:
Junior level:<60%
Industry average level: 60%~75%
Excellent level:>85%

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OEE 的三大组成部分（六大损失）
1. 时间开动率（Availability Rate）
公式：

运行时间 / 计划停机时间

（运行时间 = 计划生产时间 - 计划外停机）
衡量什么：设备是否在运行？
损失类型：
故障停机（Breakdowns）：设备突发故障维修。
换模与调整（Setup & Adjustment）：更换产品、模具、工具等导致的停机。
🔧 目标：减少非计划停机，缩短换线时间（SMED）。

2. 性能开动率（Performance Rate）
公式：

(总产量 × 理想周期时间) / 运行时间

或

实际生产速度 / 设计最大速度
衡量什么：设备运行得多快？
损失类型：
空转与小停机（Idling & Minor Stops）：短暂卡料、传感器误触发等。
速度降低（Reduced Speed）：设备未达到设计速度运行（如老化、操作不当）。
🐢 目标：消除微停机，提升运行速度接近理论值。

3. 合格品率（Quality Rate）
公式：

合格品数量 / 总生产数量
衡量什么：设备生产的产品有多少是合格的？
损失类型：
启动废品（Startup Defects）：开机调试阶段产生的不合格品。
生产废品（Production Defects）：正常运行中产生的返工、报废品。
✅ 目标：减少缺陷，提升一次合格率（FTQ）。

The three major components of OEE (six major losses)
1. Availability Rate
Formula:

Run time/planned downtime

(Run time=Planned production time - Unplanned downtime)
What to measure: Is the device running?
Type of loss:
Breakdowns: Maintenance of equipment due to sudden malfunctions.
Setup&Adjustment: Shutdown caused by changing products, molds, tools, etc.
🔧  Goal: Reduce unplanned downtime and shorten line change time (SMED).

2. Performance Rate
Formula:

(Total output x Ideal cycle time)/Running time

or

Actual production speed/maximum design speed
What to measure: How fast does the device run?
Type of loss:
Idling&Minor stops: brief jamming, sensor false triggering, etc.
Reduced Speed: The device is not operating at its designed speed (such as aging or improper operation).
🐢  Goal: Eliminate micro downtime and improve operating speed close to theoretical values.

3. Quality Rate
Formula:

Quantity of qualified products/total production quantity
What to measure: How many products produced by the equipment are qualified?
Type of loss:
Startup Defects: Non conforming products generated during the startup debugging phase.
Production Defects: Rework and scrap generated during normal operation.
✅  Goal: Reduce defects and improve first pass quality (FTQ).

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如何提升 OEE？

损失类型

改进策略

故障停机

推行TPM，加强预防性维护（PM），备件管理

换模时间长

实施SMED（单分钟换模）

小停机频繁

5S管理、自主维护、防错（Poka-Yoke）

速度降低

设备改造、操作培训、参数优化

废品率高

SPC控制、FMEA分析、首件检验、员工技能提升

How to improve OEE?
Loss type improvement strategy
Implement TPM for fault shutdown, strengthen preventive maintenance (PM), and spare parts management
Implement SMED (single minute mold change) for long mold change time
Frequent small shutdowns with 5S management, self maintenance, and error prevention (Poka Yoke)
Speed reduction equipment renovation, operation training, parameter optimization
High scrap rate SPC control, FMEA analysis, first article inspection, and employee skill improvement

whping

谢谢分享

whping

谢谢分享