IE,Q&PC,REL kpis.docx

INDUSTRIA1.EFFICIENCYOEE-FIoat1.ine21. Definition22. Explanation23. 1.ossdistribution2PRoDUCTiVITY-FIoatline21. Definition22. Explanation3MANUFACTURINGCOST31. Definition32. Explanation3ENERGYCONSUMPTION31. Definition32. Explanation4OEE-Transformationlines81. Definition82. Furtherexplanation&lossesdistribution8PRoDuCTiVITY-Transformation1.ines111. Definition112. Explanation11QUA1.ITYANDPROCESSCONTRO1.12C1.AIMS121. Definition122. Explanation123. Distributionbytype12Dedomagement131. Definition132. Explanation133. Distributionbytype14RE1.IABI1.ITY15INTRODUCTION15MAINTENANCECOSTS(4kpis)161. TotalMaintenance162. FloatFactorymaintenanceCost163. MaintenanceDept.Cost164. Divisionbytypeofmaintenance16PERFORMANCE(4Kpis)171. (NPl)Breakdownswithproductionloss172. (NP3)Breakdownswithandwithoutproductionloss173. (TRP)PreventivePlannedmaintenancecompletion4. (PIM)1.ossesofProductionformaintenanceINDUSTRIA1.EFFlaENCYOEE-Float1.ine1. DefinitionGoodProduction(tons)OEE,=Theoretical1.inePull(tons)2. Explanation GoodProduction:goodglassstackedandreadytobesenttothecustomer Theoretical1.inePull:thesmallerbetweenTheoreticalFurnacePull(tons)andTheoreticalFloatPull(tons)oTheoreticalFurnacePull: IfCullet2()%SGCVNominallDefinitionUifCuliet20%SGCVNominUlPuHI-(realculletnue-2O%)2oTheoFloatPull=Max1.ehrSpeed×ThicknessXPXNetWidth×(1+Trim.obj) Thickness：Nominalproductionthickness Netwidth:GlasswidthafteredgetrimmingoTrimmingobjective：TrimminglossobjectivedefinedbyDTIforeachthicknessoMax1.ehrspeed:Maximum1.ehrspeedachievablebythelineoGlassdensity=2,515gcmj3.1.ossdistribution100%OEEAva4abilitCOSMCf.c55.i35MCCEparametersalreadyavailablenIRISNote:YieldanditsrelatedlossesisamandatoryKPIthatisreviewedmonthlyintheGSPRODUCTMTY-Floatliner,.Goodproduction(tonnes)Productivity=：2. Explanation GOodproduction(tons)=goodglass(intonnes)stackedandreadytobesenttotheclient MH=(HoursxHeadcount)Overtime-Traininghours Headcount=Float+Warehouse+FGUFCA FGU=CostControlling+PlantDirector+HR+Purchasing+WCM FCA=Engineering+ProductionPlanning+Quality Hours:numberofhoursworkedduringtheconsideredperiodMANUFACTURINGCOST1. DefinitionManufacturingCost=R25+R31Glosspurchases2. ExplanationR25:StandardcostR31:Manufacturingandpurchasingvariancesvariancesonstandardcost)Glasspurchases：costofglassboughtfromotherSGGfactoriesENERGYCONSUMPTION1. DefinitionTheenergyKPIisdefinedasadelta(%)betweentherealspecificenergyconsumptionandthetheoreticalspecificenergyconsumptionforagivenperiod:Deltatotheo(%)=TheoreticalThisKPIisfollowedonamonthvbasisforallfactoriesandreviewedintheG5aspartoftheenergyconsumptionreductionproject.Anoteaboutthemeasurementsystem:AllinformationneededtocalculateandfollowthisKPIisfoundintheIRISsystem,includingallthecoefficientsofthetheoreticalcalculationasdefinedbySGCV.AllrealconsumptiondatashouldbetakenfromtheDCSsystemasanaccumulatedvaluefor24hours.No“spot"measurementsshouldbeusedunderanycircumstance.GasconsumptiondatashouldexcludetheconsumptionforheatinguptheFeedersandthegasusedforthethermalpurgeofregenerators,alsoanygasconsumptionintheFloatbathexitendand1.ehrshouldbeexcluded.Allotherconsumptionshouldbeincluded.2. ExplanationCalculationofthemonthlyrealspecificconsumption(Real)Themonthlytotalrealspecificconsumptioniscalculatedusingthedailyconsumptionofthethreeenergysourcesinthefurnace:gas,fueloilandelectricalboosting.SteP1：CalCUIatetherealSDeCifiCCOnSUmPtiOnforgasForgas,thedailyconsumptioniscalculatedusingthereadingsfromthegasflowmeterassociatedtothefurnace(includingthegasflowtotheworkingendburners).Thetotalmeasuredgasflowfortheday(inNm3)isthenconvertedintoitsenergyequivalentusingthegas,NHV(NetHeatingValue,inkcalNm3).Finally,thisenergyvalue(inkcalisdividedbytheequivalentpullat20%cullet(inkg)fortheday,resultingintherealgosspecificconsumption(inkcal/kg):r'''EqttivaleiitPuUSteP2:CalCUlatetherealSPeCifiCconsumptionforfuelOilForfuel,thedailyconsumptioniscalculatedusingthereadingsfromthefueloilflowmeterassociatedtothefurnace.Thetotalmeasuredflowfortheday(inkg)isthenconvertedintoitsenergyequivalentusingthefueloil'sNHV(NetHeatingValue,inkcal/kg).Finally,thisenergyvalue(inkcalisdividedbytheequivalentpullat20%cullet(inkg)fortheday,resultingintherealfuelspecificconsumption(inkcal/kg):也32"EquivalentPullSteP3:CaICuIatetherealSPeCifiCCOnSUmPtiOnforelectricalboostin以Fortheelectricalboostingitissomewhatsimpler,sincethe“electricalflow“totheelectrodesisalreadygiveninkilowatts.Thetotalamountofelectricalflowduringtheday(inkWh)isconvertedintokcalusingtherelationship1kWh=860kcal.Finally,thisenergyvalue(inkcal)isdividedbytheequivalentpullat20%culletikg)fortheday,resultingintherealelectricalspecificconsumption(inkcal/kg)：_fEieciricaIFiow<kWlt)×860Keti1.lfcniri.=e*EiiuivalentPu