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

- 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”.

Initial Situation Objectives Approach Summary Content

Initial Situation Objectives Approach Summary Content

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: 2,55 5,32 7,82 Staff Costs 11,14 Acquisition Costs q Maintenance Costs Tool Costs Energy and Running Costs Energy and Running Costs 17,02 56,15 Other Costs Krawitz, Augsburg, 7.10.2004 Initial Situation: 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. a sta da d at o o t e ac e bu de s ecessa y � the base is development of a new approach for the machine user. Initial Situation Objectives Approach Summary

Initial Situation Objectives Approach Summary Content

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

Initial Situation Objectives Approach Summary Content

Approach - Ratio for measurement - What is the main point in which a machine user is interested before his new purchase? new purchase? Unit Price ∑ Benefit Approach for the machine builder: = = LC � Creating a new Index: LCP � Creating a new Index: LCP. LCP LCP ∑ Costs LC Initial Situation Objectives Approach Summary

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. Sources and fields of data for the determination of the LCP Index. Initial Situation Objectives Approach Summary

Buildings and Infra astructure Buildin ngs and Infra astructure Initial Situation Initial- Costs Initial-Costs Machine ery Machine ry Life-Cycle-Cost (LCC) - Prognosis of LCP - Approach Installatio on Installation n Tr raining -C Costs Training T - Co osts Alterati ion and M odification n Alterati on and Mo odification n Objectives Ene ergy, Tools s … Operating-Costs En nergy, Too ols … Operating Labor -Co osts Labor- Cos sts Mainten ance -Cos st (Person n) Mainte enance Cost - t (Person) -Costs Unit Price Unit Price Maintena ance -Cos st (Materia al) Mainte enance Cost - (Material) ) Approach * * * Effectiveness (OEE) Theoretical Output O Overall Equipment Actual Output Quality Problems, … Procedure, Organization, … MTBF, MTTR, … Performance Rate Quality Rate ll E Availability Summary i t

Approach - Prognosis of LCP - Estimation of the LCC Estimation of the benefit Availability e l) e s and I nfastructure n on and Modification ) l) n on and Modification ) ance-Cost ( Person) ance-Cost (Material nance-Cost ( Person ance-Cost (Materia * * gs and I nfastructur Performance Rate nergy, Tools … ergy, Tools … raining-Costs raining-Costs Labour-Costs Labour-Costs I nstallation I nstallation Macninery Macninery * Quality Rate Alteratio Maintena Maintena Alteratio Maintena Tr L Building I En L Mainten Building T En Overall Equipment Effectiveness (OEE) * Theoretical Output Initial-Costs Operating-Costs Initial-Costs Operating-Costs Life-Cycle- Life-Cycle- Cost Cost Actual Output [ [ ] ] ( ( ) ) ∑ ∑ ∑ ∑ ∑ ∑ ∑ ∑ = Δ ∗ = Benefit f Output p t OEE + Costs Costs Costs Costs theoretica theoretica l l Pr Pr oduct oduct Pr Pr oduct oduct Pr P oduct d independin d d g LC Pr oduct LC LC 1 = ∗ Δ ⎛ ⎞ Output t ∑ ∑ ⎜ ⎜ ⎟ ⎟ ∫ ∫ theoretica theoretica l l Pr Pr oduct oduct FixedCycle Fi dC l Costs ( t ) dt ⎜ ⎟ Pr oduct depending ⎝ Δ ⎠ Pr oduct ∫ t Pr oduct OEE ( t ) dt Δ = = t OEE OEE Pr oduct Δ Pr oduct t Pr oduct Initial Situation Objectives Approach Summary

Approach - Prognosis of LCP - Output Life-Cycle-Cost (OEE) Unit Price ⎡ ⎤ 1 ∑ ∑ ∫ ∫ ∗ ∑ ∑ ⎢ ⎥ OEE ( t ) dt Benefit f ⎢ ⎢ ⎥ ⎥ FixedCycle FixedCycle ⎣ ⎣ ⎦ ⎦ Δ Pr oduct = = t Pr oduct LC LCP ∑ ⎛ ⎞ [ [ ] ] Costs ∑ ∑ ∑ ∑ ⎜ ⎟ ∫ ∫ + Costs Costs ( ( t ) ) dt ⎜ ⎜ ⎟ ⎟ LC Pr Pr oduct oduct independin independin g g Pr Pr oduct oduct depending depending ⎝ Δ ⎠ LC Pr oduct t oduct Pr Initial Situation Objectives Approach Summary

Approach - Prognosis of LCP - OEE = Availability * Performance Rate * Quality Rate Main considered Reliability Downtime Failures aspects: Data Number of failures N b f f il MTBF Running Breakdown Running Running Breakdown MTTR Failure Failure Technician Failure Resources Starting Repaired Occurrence Communication on-site detected are available Initial Situation Objectives Approach Summary

Approach - Prognosis of LCP - Machine Structure Data Collection Reliability Model Model and Analysis and Analysis Analysis Analysis Malfunction behavior FMEA (Weibull analysis) / Experts p Builder After Sales Service Machine Test & Simulation M Spare part sales ser Reliability chine Us Operating Parameters data & Period of Repair Maintenance Maintenance Mac data Initial Situation Objectives Approach Summary

Approach - Perspective: Structured approach � Condition Monitoring - The two presented dimensions for the calculation of the unit price are: Life-Cycle-Costs Productivity (OEE) Unit Price Goal: Model for prediction and controlling of the reliability and maintainability of machines and plants over the Life-Cycle. Third Dimension: Life Cycle Costs Life-Cycle-Costs Productivity (OEE) Productivity (OEE) Monitoring Monitoring Life-Cycle- Life-Cycle- Performance Management Initial Situation Objectives Approach Summary

Approach - Perspective: Structured approach � Condition Monitoring - Life-Cycle-Performance Management : Reference model (3 ranks). y g ( ) Monitoring MPM MPM MPM MPM actual a Productivity P d ti it OEE OEE OEE OEE OEE OEE OEE Felddaten- Ausw ertung Maßnahm en Review erfassung actua Life - Cycle - Costs LCC LCC LCC LCC Felddaten- Ausw ertung Maßnahm en Review erfassung al target actual– actual Record I nter- Actions Review Analysen Synchr. KVP Controlling pretation targe actu Synchr. y ual– Analysen Analysen KVP KVP Controlling Controlling et target actual– target Kunden- Synchronize Analysis Am elioration Controlling Markt, MPM- Risiko- spez. tar R&D Analyse analyse Prognose rget Markt, Pflichten- Lasten- Risiko- R&D heft heft analyse targe Custom er Structural Risk- R&D et analysis analysis requirem ents requirem ents anal sis analysis Initial Situation Objectives Approach Summary

Initial Situation Objectives Approach Summary Content