Improve Asset Productivity at HRC Lean Manufacturing Pilot Kick-off Document – Monthly Maintenance Improvement.pptVIP免费

BS/020626/SH-Maintenance(2000)CONFIDENTIALImproveAssetProductivityatHRCLeanManufacturingPilotKickoffDocument–MonthlyMaintenanceImprovementBaosteelThisreportissolelyfortheuseofclientpersonnel.Nopartofitmaybecirculated,quoted,orreproducedfordistributionoutsidetheclientorganizationwithoutpriorwrittenapprovalfromMcKinsey&Company.ThismaterialwasusedbyMcKinsey&Companyduringanoralpresentation;itisnotacompleterecordofthediscussion.June17,2002BS/020626/SH-Maintenance(2000)2TABLEOFCONTENT•DiagnosticresultsofmonthlymaintenancetimeimprovementpotentialatHRC•Aspirations,approaches,andworkplanformonthlymaintenancetimereductionatHRCBS/020626/SH-Maintenance(2000)3ANNUALANDPLANNEDMAINTENANCEREQUIRESSIGNIFICANTAMOUNTOFTIMEANDISABIGPORTIONOFPLANNEDDOWNTIME876035041394028454067734366233121560857975056(365)days1517391228223360*241568**233HoursImprovementpotentialareaImprovementpotential:1,527H3552***23210274186570Sixmaintenancesfor59hourswereaddedduetoreplacementofcrossingin2001*Thespeedlossastheactualspeednotachieveaveragespeed（426hour）;singlefurnace/machineoperationcalculatedas1/3loss10hour）**FinalblockrateWithscrapededucted**incl.rework,downgrade,unplannedWIP(Replenishmenthoursdeducted)Source:Baosteel;McKinseyanalysisNetvaluableproductiontimewith75%capacityutilizationachievedRe-worktimeYield(incl.Scrap)Speedloss*TotalOpera-tingtimeUn-planneddowntimeTotalavail-abletimeBackuprollchangetimeWorkrollchangetimePlannedmain-tenanceAnnualmain-tenanceTotalcalendarhourEffectiveoperatingtimePlannedproductiontimerate77.3％Availabilityrate92.0％Performancerate93.0％Qualityrate87.2％OEE＝NetvaluableproductiontimeTotalavailabletime＝74.6％Capacityutilization＝PlannedproductiontimerateXOEE＝57.7％Bestpractice80-85%70-75%Repleni-shmenthoursNetproduc-tiontimeNetvaluableproductiontime1,580capacityutilizationandOEEBS/020626/SH-Maintenance(2000)45897125120636021869365762688393573608760ANNUALANDPLANNEDMAINTENANCEREQUIRESSIGNIFICANTAMOUNTOFTIMEANDISABIGPORTIONOFPLANNEDDOWNTIME*Thespeedlossastheactualspeednotachieveaveragespeed（194hour）;singlefurnace/machineoperationcalculatedas1/3loss（24hour）**FinalblockrateWithscrapededucted**incl.rework,downgrade,unplannedWIP(Replenishmenthoursdeducted)Source:Baosteel;McKinseyanalysis(365)days151535112892426525555237Hours6142**Improvementpotential:1204H532***5365657022274223*OEE＝NetvaluableproductiontimeTotalavailabletime＝77.4％Capacityutilization＝PlannedproductiontimerateXOEE＝61.2％Bestpractice80-85%70-75%Plannedproductiontimerate79.2％Performancerate96.6％Qualityrate87.4％Availabilityrate91.7％Netvaluableproductionwith75%capacityutilizationachievedRe-worktimeYield(incl.Scrap)Speedloss*TotalOperatingtimeUnplanneddowntimeTotalavail-abletimeBackuprollchangetimeWorkrollchangetimePlannedmain-tenanceAnnualmain-tenanceTotalcalendarhourEffectiveoperatingtimeReplenish-menttimeNetproduc-tiontimeNetvaluableproductiontimeImprovementpotentialarea2,050capacityutilizationandOEEBS/020626/SH-Maintenance(2000)5212212168364200416245245168336200336ANNUALMAINTENANCEANDMONTHLYMAINTENANCETIMEATHRCHASLARGEREDUCTIONPOTENTIAL1580annualmaintenancehourshour20012002targetsstretchedtargets2050annualmaintenancehourshour58158136862857636820012002targetsstretchedtargetssource:Baosteel;McKinseyexpertinterviewTargetsin2002•Currently,1580hasoneannualmaintenanceevery18months,2majorplannedmaintena...