Designing Production Systems to Truly Leverage High-Cost Manufacturing Equipment (Part 1)
What is "availability," which influences the investment effectiveness of high-cost equipment?
Given the introduction of expensive manufacturing equipment, it is natural to think, "I want to minimize downtime and maximize utilization." However, simply increasing the time the equipment is running does not necessarily lead to improvements in the overall productivity or profitability of the factory. An important aspect to consider when thinking about equipment utilization is to differentiate between "availability rate" and "operating rate." The "availability rate" refers to the percentage of time the equipment is in a state where it can be operated without being stopped due to failures, abnormalities, maintenance, or inspections. On the other hand, the "operating rate" is the percentage of time that the equipment is actually given work to do and is processing products. The first step should be to reduce the "non-operational time" of the equipment and bring it closer to a state where it can be used at any time. To achieve this, it is important to analyze and address the causes of downtime from the perspective of QC, maintenance, troubles, alarms, and including setup in "QMTA + S." This document will explain the differences between "availability rate" and "operating rate," as well as how to perceive equipment downtime, in order to maximize the investment effect of high-cost equipment.
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