Improve Asset Productivity at HRC Lean Manufacturing Pilot Kick-off Document – Roll Change improvement.pptVIP免费

BS/020416/SH-WZ(2000)CONFIDENTIALImproveAssetProductivityatHRCLeanManufacturingPilotKick-offDocument–RollChangeimprovementBaosteelThisreportissolelyfortheuseofclientpersonnel.Nopartofitmaybecirculated,quoted,orreproducedfordistributionoutsidetheclientorganizationwithoutpriorwrittenapprovalfromMcKinsey&Company.ThismaterialwasusedbyMcKinsey&Companyduringanoralpresentation;itisnotacompleterecordofthediscussion.June17,2002BS/020416/SH-WZ(2000)2TABLEOFCONTENT•DiagnosticresultsofrollchangeimprovementpotentialatHRC•Aspirations,approachesandworkplanforrollchangeimprovementatHRCBS/020416/SH-WZ(2000)3TABLEOFCONTENT•DiagnosticresultsofrollchangeimprovementpotentialatHRC•Aspirations,approachesandworkplanforrollchangeimprovementatHRCBS/020416/SH-WZ(2000)41580CAPACITYUTILIZATIONANDOEEVS.WORLDLEADINGPERFORMANCE,THEREISSOMEGAP876035041394028454067734366233121560857975056(365)days1517391228223360*241568**233HoursImprovementpotentialareaImprovementpotential:1,527H3552***23210274186570Sixmaintenancesfor59hourswereaddedduetoreplacementofcrossingin2001*Thespeedlossastheactualspeednotachieveaveragespeed（426hour）;singlefurnace/machineoperationcalculatedas1/3loss10hour）**FinalblockrateWithscrapededucted**incl.rework,downgrade,unplannedWIP(Replenishmenthoursdeducted)source:Baosteel;McKinseyanalysisNetproductionhoursofacceptableproductswith75%capacityutilizationachievedRe-workhoursYield(incl.Scrape)Speedloss*TotalrunninghoursFailureandun-plannedshutdownTotalavail-abletimeChangesupport-ingrollChangeworkingrollPlannedmain-tenanceAnnualmain-tenanceTotalcalendarhourEffectiverunninghoursPlannedproductiontimeratio77.3％Availableproductiontimeratio92.0％Effectiveproductiontimeratio93.0％On-specproductiontimeratio87.2％OEE（OEE）＝NetproductionhoursTotalavailabletime＝74.6％capacityutilization率＝plannedproductiontimeratioXOEE＝57.7％worldleadingperformance80-85%70-75%Repleni-shmenthoursNetproduc-tionhoursNetproductionhoursofacceptableproductsBS/020416/SH-WZ(2000)52050CAPACITYUTILIZATIONANDOEEVS.WORLDLEADINGPERFORMANCE,THEREISSOMEGAP*Thespeedlossastheactualspeednotachieveaveragespeed（194hour）;singlefurnace/machineoperationcalculatedas1/3loss（24hour）**FinalblockrateWithscrapededucted**incl.rework,downgrade,unplannedWIP(Replenishmenthoursdeducted)source:Baosteel;McKinseyanalysis5897125120636021869365762688393573608760(365)days151535112892426525555237HoursImprovementpotentialarea6142**Improvementpotential:1204H532***5365657022274223*OEE（OEE）＝NetproductionhoursTotalavailabletime＝77.4％capacityutilization率＝plannedproductiontimeratioXOEE＝61.2％worldleadingperformance80-85%70-75%Plannedproductiontimeratio79.2％Effectiveproductiontimeratio96.6％On-specproductiontimeratio87.4％Availableproductiontimeratio91.7％Netproductionhoursofacceptableproductswith75%capacityutilizationachievedRe-workhoursYield(incl.Scrape)Speedloss*TotalrunninghoursFailureandun-plannedshutdownTotalavail-abletimeChangesupport-ingrollChangeworkingrollPlannedmain-tenanceAnnualmain-tenanceTotalcalendarhourEffectiverunninghoursReplenishmenthoursNetproduc-tionhoursNetproductionhoursofacceptableproductsBS/020416/SH-WZ(2000)6840504420WORKROLLCHANGETIMEATHRCHASHUGEPOTENTIALFORIMPROVEMENT*ChecktimenotincludedSources:BaosteelLtd.；Baosteelinternalinterview；McKinseyexpertinterview；Fieldviewandtimecountingofrollchanging1580timeofcha...