Iziphi izindlela zokubonakalisa okunyanisekile ukubonakalisa kwezinkambo zokuvula kuzinyama ukufuna ukuphutha kwezindawo zokusebenza?

Ukujabula Okufundwa Ngokwesibonelo Ukuthi Yini Okubiza Ukuphila Kwesikhathi Sokusebenza

Ukuphila kwezindawo zokulima kungakhathali ukuthi amotori ayadlula kuphela. Kuyinto yokukhuselela izinto ezingavunyelwa, ukumenelela imikhombolo yezindlela zokusebenza ezinamandla okwesikhathi esihle, nokukhuluma isibopho sokubambisana esingasemva kokuba indawo eyodwa iyabeka futhi izilwane ziyabuka emuva kwezinhlobo. Uguqulo phakathi kwendawo ene-85% yokuphila nokwenye ene-65% akuyi ngokufundisa—kubonakala ngqo kwezindaba zasekhaya zezinsizwa.

Umsebenzi woku-2021 wenza kwezindawo zokulima ePeru wabonisa ukuthi ukugxila i-Learn Manufacturing ne-Total Productive Maintenance (TPM) kwenza ukuthi kukhona ukuvutha kwezinkambo zokuphila kwezinhlobo ngokulinganisa ngo-5.87%. Lokho okukhona akakwaziwa ngokuzwa. Kuyakwaziwa ngokujabula izinkambo ezifanele nokwenza izinto ngazo.

Ukuphila Kwesikhathi Sokusebenza Ngokuphelele Ngokwesibonelo Sokuphambili

Ukuphila Kwesikhathi Sokusebenza Ngokuphelele (OEE) uyisimo esihlukileyo esisetshenziswa ngempela ukubhalisa ukuphila kwezinhlobo kwezindawo zokulima. Kuyahlukwa ku-mi-3: Ukuphila, Ukusebenza, Nokuhle kusilwana kwesikhumbuzi, Ukuthi i-‘Availability’ ishice kuthi ilayini iyasebenza lapho kufanele isebenze. I-‘Performance’ ishice kuthi iyasebenza ngokwezinkundla zokusebenza eziqondiswe. I-‘Quality’ ishice kuthi iphrojekthi iyakwazi ukuphikisa iziphakamiso—akukho ukungcoliswa, akukho ukuchithwa kakhulu, akukho ukuthi iphrojekthi ibe yincinane.

Okwenza i-OEE ibalulekile kubukhali bokushisa kuthi ngokuthi isibonelo sokuvumela ukuxoxa ngokuthi phyakade izinkinga ziyagqoka kuziphi. Isikhumbuzi esinye singakha 90% ye-‘Availability’ kodwa kuphela 75% ye-‘Performance’ ngoba isikhumbuzi sesikhathi sokugqibela asikwazi ukulandela isikhathi sokuhambisa amasikhumbuzi. Isikhumbuzi esinye singahamba ngokwezinkundla zokusebenza kodwa singathola 5% yamabili ngokuthi kunezinga le-‘Quality’ ngoba isikhumbuzi sokuvula isikhathi asisendaweni efanayo. Uma akukho i-OEE, lezi zinkinga zibonakala njengamazinga okwesibili. Uma kukho i-OEE, zibonakala njengamazinga okwesinye ongasho ukubona.

I-‘Availability’: Umphumela Wokusebenza Oqala Ngokuthi Kuyinto Yokuqala Nokuthi Akuyinto Yokuqala

Ukutholakala kubizwa ngokuthi isikhathi sokusebenza esenzekileyo sivulwe ngokuthi isikhathi sokuprodukha esithathelwe. Ngokwesibonelo, lokhu kusho ukuthi kufuneka kubhalwe isikhathi sonke isilayini ishiya—futhi kufuneka kubhalwe ngokuthi yini.

Isikhathi sokushiya esithathelwe kufaka izishishini zokuhlanza, izishishini zokuguqula izisifundo, futhi izishishini zokuhlola okuthathelwe. Isikhathi sokushiya esingathathelwe ngu-where the real leverage sits: izinhlobo zokugqoka, izihlukanisi, izilinganiso zokuphazimula kwamandla, futhi iziphulo zomsebenzisi. Kusukela ekuvalekeni kwezinkambo zokuphatha inkolo, umsebenzi wokuqala wabizwa ngokuthi ukutholakala kwezindawo/izinkambo, ukusebenzisa isikhathi esitholakala, futhi isivinini sokuprodukha. isiqinisekiso esibalulekile? Izindawo eziphumelela zizoba zikholwa ukuthi ziyatholakala ngempela ngoba azikwazi ukubhala ngokuphelele izishishini ezincinci—ezinye ezithi amasekhondi e-30 athi kuzoba kunezinye ezithi amashumi ayisikhombisa ngohouru, futhi kuzoba kunezinkinga ezingaphezulu ngemuva kokusha.

Indlela eyodwa: fundisa izinhlayisi zokuthwala izimboni kwezindawo eziphambili zokuthwala. Isibonelo sesikhulu sezinkampani zokuphatha izinhliziyo emhlabeni waseMidwest sasho ukuthi 40% yezindleko zokungathwaliwa ngokomlando zazisendaweni esiphambili phakathi kwe-scalder ne-picker. Indlela yokusiza ayikabona izinkampani ezintsha—kwasukela ukuguqula isikhathi se-conveyor futhi ukongeza i-guide rail engeyodwa. Ukufinyelela kwakhosela kusukela ku-82% ku-89% ngeminyaka miyane.

Ukusebenza: Izinkinga Zokugcina Ispeed Ezithile Ngaphandle Kwesibonelo

Ukusebenza kuchazela ukuthi ukuthwala okwenzekayo kushiywa ngokwesikhathi sokuthwala okulinganayo. Uma umkhala ushiywe ukuthwala amadoda angu-10,000 ngamuhla kodwa kushiywa ngokuphelele ngamadoda angu-8,500, lokhu kukhona ukungasebenzi kwe-15%.

Isilungiselelo esikhulu kuyilo lokuba iziphelo zokusebenza ziyagcina kusukela. Abasebenzi bakhuluma ukuthi baphumelela ngokushesha ngokwesithakathi “lokhu kukhona ukuthi lezinkambo zihamba njengalokho” noma “izinyoni zingabili kuleli gqambo.” Kodwa lezi zizindikimba zizifihla izindlela ezinamandla. Umsebenzi wokufunda ukuthi ukubhala kwezinkambo zokuphatha kwezinkambo zokuphatha kwakwenzeka ukuthi kubonakala izinto ezintathu ezingavunyelwa kwe-OEE—ukutholakala, ukusetshenziswa, nokuthatha isikhathi—futhi kubonakala ukutha kuzoba kubhalwa ngokushesha ngokwesikhathi ngokuthi akukho inzuzo yezinkambo zokuthatha isikhathi .

Emasithakathini okuphatha izinkambo, iziphelo zokusebenza ziyagcina kusukela kulezi zindikimba:

1. Izinyoni ezingafanani ukusuka kwezinyoni okuzosika ukuthi izinkambo zibaleka noma zisikele

2. Amathooli evile kwezinkambo zokuphatha noma zokuvula

3. Ukuphela kwesithakathi sokuhlungu emisithakathini yokuhlungu

4. Ukuchaza kwebhodhi yomsebenzi emisithakathini yokuvula ngokwesibhali

Ukuthintela kusobala ngokubhalisa isikhathi sokusebenza kwisikhathi esithile, ngosuku, ngomkhosi. Uma lokhu cidla kunezinto, izizwe zokwenza ubudlela zibonakala.

Ubukhulu: Isiphetho Esithinta Ngqo Ukuvumela Nokuphatha Kwesivuno

Ubukhulu ngokwesiphetho se-OEE sisho ukuvumela okwesokuqala—ukuthi iprodukthi ibuyela ngokufanele ngaphandle kokuzenzela kabusha noma ukugcina. Kwisifazilho, izinkinga zokubukhulu zibonakala njengazo:

● Amakhanda asihlwa okufuneka ukuthathwa amasimbi noma ukuthathwa ngokuphuma

● Ukungathathwa konke kwezinyama okubangela ukuthatha kabusha ngendlela yomuntu

● Ukubulawa kweskin kusukela ekuscalding noma ekupicking engafanele

● Izinhlaka zokubhala ezingafanele kwezinhloko zokubhala

Lokhu kubiza ngokukhulu ngoba inhliziyo yayisebenziwe kakhulu. Ikhanda elisindisiwe leliyinkambo yokuphatha kuphela—kuyinkambo yezindlela, amanzi, amandla, nokutha kwezinye izinto ezenziwe kakhulu ukuze loku kufikele.

Izindlela zesiNtshisekelo se-ASTM, kusukela ku-Volime 15.12, zinikeza izihlalo zokubala ukusebenza kwezinkambo nezinkambo zokuhambisana ngokuphelele kwezinkambo zokuhlola izilwane zemifula nezilwane zemilili. Lezi zindlela zibaluleka ngoba zibeka izimfuneko zokwesibonelo sokuthi ukuthi izinkambo zokubala kufanele zisebenze njani—futhi lokhu kubangela ubukhulu bokuchaza ubukhulu.

Ukubhalwa kwezinkambo zokungasebenzi: Iqiniso eliqinisa i-OEE ukuba libe yinto esingayikwenza.

I-OEE yisihloko. Ukubhalwa kwezinkambo zokungasebenzi yisibongo esifanayo nalo.

Ungakazi ngaphi umkhosi wakhiwe, i-OEE yizigama kuphela. Izilwane ezinamandla kakhulu zihlola zonke izinkambo zokungasebenzi ngokwesikhundla sokuthi:

● Uhlobo lwesinkambo (umthwasa, umhlolisi wezinyawo, umsitha wokuchitha, umthwasa wokugcina)

● Umhlobo wokungafani (wokuzimela, wokuzimela kwesikhathi, okuthiwe ngumsebenzisi, okuthiwe ngomthwalo)

● Usuku (ngaphezukwesikhathi esingapansi kweziminzuzo ezingu-5, iziminzuzo ezi-5 kuya kweziminzuzo ezi-30, ngaphezukwesikhathi esingapansi kweziminzuzo ezi-30)

● Isikhathi sesandla (isikhathi esikade kakhulu emva kokuvula, ngaphambi kokudla lwesikhathi, emva kokudla lwesikhathi, emva kokugcina umsebenzi)

Indawo yokuqala yokudla kwisifundazwe saseNtshonalanga yasemthwakazi isikhathi sokungasebenzi kusendulo ngama-90 futhi yafumana ukuthi i-60% yezikhathi zokungasebenzi kakhulu zazihlala phakathi kwe-11:00 AM kuya kwe-1:00 PM—akunakho ubungakanani bezinkambo, kodwa ngoba izishesho zokucima kwezinkambo zazihlanganiswa kahle nesikhululeko sakwamakhubu. Ukuguqula ukuphakanyiswa kwezishesho zokucima kwezinkambo kusenzo isikhathi sokungasebenzi esingavakalanga ngamaminithi e-40 ngosuku. Lokhu kuyizikhathi ezi-240 zokusebenza ekhaya ngonyaka.

Isikhathi esisodwa phakathi kokufa nokubuyisela kanye nesikhathi esisodwa ukubuyisela

I-MTBF ne-MTTR nguizimetric zokusebenza ozokubeka ku-Availability. I-MTBF ibonisa ukuthi inkambo iyisiphi esinamandla. I-MTTR ibonisa ukuthi amandla akho ayisiphi esibuyisela kusenzo kahle.

Ezindaweni zokuhlatshwa, i-MTBF ivame ukuba phansi kakhulu emishini enezingxenye ezihambayo ezimweni ezimanzi, ezibandayo noma ezihlabayoizitshisi, abaqoqi kanye nama-eviscerator. I-MTTR ivame ukuba yinde kakhulu emishini enezixhumanisi eziyinkimbinkimbi noma izinhlelo zokulawula ezizimele.

Isifundo esisebenzayo: qapha i-MTBF ne-MTTR ngohlobo lwemishini nangokushintsha. Uma i-MTTR yinde kakhulu emsebenzini wasebusuku kunasemini, lokho kuyinkinga yokuqeqeshwa noma yabasebenzi, hhayi eyokusebenza. Uma i-MTBF yehla phakathi nezinyanga zasehlobo, lokho kuyinkinga yokushisa noma yomswakama edinga ukulawulwa kwemvelo, hhayi nje ukugcinwa.

Ukusetshenziswa Kwezwe Langempela: Isibonelo Esivela Ensimini

Isikhungo esisebenza ngezimvu ezingu-15.000 ngehora esisemaphandleni sisanda kuqalwa ukusebenza ngomugqa owodwa ozenzakalelayo owenzelwe ukusebenza kahle . Ithimba labaphathi labeka ukugcizelela okukhethekile ekwenzeni ngcono inqubo yokukhishwa kwamathumbu, litshale imali emishini enezinto ezihlanganisiwe zokuthwebula idatha ezenza kube lula ukuqapha ukukhiqizwa ngesikhathi sangempela . Isisistemu sivumela abasebenzisi ukwenza izilungiselelo ezitholakala kusuka kwezindata ngokushesha, ukuvutha ukugcina kwezindawo zokusebenza nokuphula ukungasebenzi .

Okukhuthaza le ndlela yokusebenza kwaba yisikhombisa kwezinto eziphezulu ne-ukujabula okuphezulu. Iplanti ayikwazi ukufaka isisitemu sokulandela kuphela—kodwa yabelana imithombo yokuqonda ngokuzenzakale. Abasupervisa beshift baye kule mithombo ngokubiza izizathu zonke zokungasebenzi okungenani eminyakeni engu-10. Ngeminyaka eyi-3, i-Availability yavutha ngama-6%, futhi iplanti yafika ekutholeni kwakho kwezindawo zokusebenza ngokuphathelene nesikhombisa ngokwesibili.