Detail of GB/T 23023-2022

Introduction of GB/T 23023-2022

1 Scope This document constructs a set of production equipment operation performance evaluation indicators, gives the classification of production equipment operation performance evaluation indicators, indicator descriptions, calculation methods and optimization improvement measures, and stipulates the general requirements for indicator data collection. This document is applicable to different industries, different types and sizes of enterprises owning and using production equipment for the digital transformation of production equipment operation performance evaluation, and provides reference for production equipment manufacturers, suppliers and operation and maintenance service providers. 2 Normative references The following documents constitute essential provisions of this document by means of normative references in the text. Where a reference is dated, only the version corresponding to that date applies to this document; where a reference is not dated, the latest version (including all amendments) applies to this document. 3 Terms and definitions The terms defined in GB/T 23021-2022 and the following terms and definitions apply to this document. 3.1 Statistical periodl The time interval used to calculate the performance evaluation indicators for the operation of production equipment. 4 Abbreviations The following abbreviations apply to this document. 5 Classification of indicators 5.1 Overview The production equipment operation performance evaluation indicators are divided into four main categories, namely production operation indicators, repair and maintenance indicators, energy and material indicators and safety and environmental indicators, as shown in Table 1. 5.2 Production operation indicators Production operation indicators mainly reflect the performance and output of production equipment in the process of operation, and the representative indicators are the comprehensive efficiency of production equipment, production equipment capacity utilization rate, production equipment input-output ratio and production equipment process capability index. 5.3 Repair and maintenance indicators The indicators of repair and maintenance mainly reflect the performance of repair and maintenance in the operation of production equipment, and the representative indicators are downtime rate. Average time between failures. Average repair time. Maintenance cost rate, spare parts inventory turnover rate. 5.4 Energy and Materials Indicators The energy and material indicators mainly reflect the performance of energy and material consumption in the operation of production equipment, and the representative indicators are integrated energy consumption per unit of output value and raw material utilization rate. 5.5 Safety and environmental protection indicators The indicators of safety and environmental protection mainly reflect the performance of safety and environmental protection in the operation of production facilities, and the representative indicator is the average duration of safe production. Waste emission per unit of production value. Pass rate of hazard detection. 6 Description of indicators, calculation methods and improvement measures 6.1 Production and operation indicators 6.1.1 Overall efficiency of production equipment 6.1.1.1 Description of indicators The overall efficiency of production equipment is the product of the time start rate, performance start rate and product qualification rate of production equipment in the statistical period, which is the ratio of the actual capacity of production equipment to the theoretical capacity. 6.1.1.2 Calculation method The calculation method for the overall efficiency of the production equipment is shown in equation (1). 6.1.1.3 Optimisation and improvement measures It is advisable to use digital means to carry out data collection, health management, dynamic scheduling and product quality control of production equipment to optimise and improve this indicator in a targeted manner: a) Use of automated monitoring systems such as DCS, MDC and SCADA to collect data on the operating status of production equipment, production progress, production capacity and output, product quality, etc., and to visualise and analyse the whole process of production equipment operating data; b) To carry out health status assessment, fault warning and predictive maintenance of production equipment, develop a production equipment health management model library, and ensure the continuous. Stable and efficient operation of production equipment, to improve the time start-up rate; c) Monitoring and control of the operating load of production equipment. c) Monitoring, control and balance scheduling of production equipment, developing an intelligent scheduling model algorithm for production equipment to achieve c) monitoring, controlling and balancing the operating load of production equipment, developing intelligent scheduling algorithms for production equipment, realising dynamic adjustment, precise execution and intelligent optimisation of production capacity planning, and improving the performance start-up rate; d. Total quality management activities through quality management tools such as FMEA, QMIS and SPC to provide early warning of factors affecting product quality in the production process. dTotal quality management activities through FMEA, QMIS, SPC and other quality management tools. d. To carry out total quality management activities through FMEA, QMIS, SPC and other quality management tools to provide early warning of factors affecting product quality in the production process. 6.1.2 Capacity utilisation of production equipment 6.1.2.1 Description of the indicator The production equipment capacity utilisation rate is the product of the overall efficiency of the production equipment and the production equipment load factor in the statistical period, which is an important indicator to reflect the overall performance of the production equipment. 6.1.2.2 Calculation method The calculation method of production equipment capacity utilization rate is shown in equation (5.). 6.1.2.3 Optimisation and improvement measures It is advisable to use digital means to monitor the status of production equipment, optimise the load of production equipment and ensure the continuous operation of production equipment to optimise and improve this indicator in a targeted manner, including but not limited to a) Adopt automated monitoring systems such as DCS, MDC and SCADA to collect data on production equipment and to achieve real-time monitoring of the operating status of production equipment and quantification of indicators. a) The use of DCS, MDC, SCADA and other automated monitoring systems to collect data related to production equipment, so as to achieve real-time monitoring and quantitative management of the operating status of production equipment; b) To analyse the production capacity and output of production equipment, calendar scheduling, processes, tasks and operators, and to develop intelligent scheduling models and algorithms. scheduling model algorithm, to achieve the optimal allocation of production equipment working hours, continuous optimization of production equipment load; c) Based on the historical data of production equipment operation, we will analyse the downtime loss caused by factors other than production equipment itself (e.g. waiting for scheduled production, waiting for up/down processes, water and electricity outages, gas outages, etc.), and ensure the continuous, stable and efficient operation of production equipment through dynamic scheduling of production equipment tasks, close connection of up/down processes, and production guarantee capacity enhancement. 6.1.3 Production equipment input-output ratio 6.1.3.1 Description of indicators The input-output ratio of production equipment is the ratio of investment in production equipment assets to industrial output value in the statistical period, which is an important indicator reflecting the relationship between investment in production equipment assets and the value created by them. 6.1.3.3 Optimisation and improvement measures Enterprises should adopt digital means to carry out statistical analysis of production equipment input and output data, input strategy optimization, output efficiency improvement, etc. to optimize and improve this indicator in a targeted manner, specific measures include but not limited to a) Collect, calculate and analyse production equipment input and output data from ERP.EAM.MES and other information systems, and automatically calculate The investment cost of production equipment and the industrial output value of production equipment in the statistical period; b) for the production equipment input materials. Energy, personnel, spare parts and other data mining analysis, the establishment of production equipment input strategy model library, based on the model dynamic adjustment of production equipment material supply, energy consumption control, scheduling and other measures, to achieve dynamic optimization of production equipment input strategy adjustment; c) quantify and analyse the production capacity and output, product quality and maintenance records of production equipment. c) Quantitative analysis of production equipment capacity and output, product quality, maintenance records and other data to build a production equipment capacity control c) Quantitative analysis of production equipment capacity, product quality, maintenance records and data, construction of production equipment capacity control cockpit, based on the model to give suggestions on strategies to optimize the industrial output of production equipment. 6.1.4 Process capability index for production equipment 6.1.4.1 Description of the index The ability of the production equipment to maintain its basic functional characteristics constant over time during the statistical period, also refers to the ability of the production equipment to produce products with characteristics that do not change over time - 6.1.4.2 Method of calculation The calculation method is divided into the following three forms. 6.1.4.3 Optimisation and improvement measures Enterprises are advised to use digital means to carry out statistical analysis of product specifications, production process control optimisation and overall product quality control to optimise and improve this indicator in a targeted manner, including but not limited to:, 6.2 Repair and maintenance indicators 6.2.1 Downtime rate 6.2.1.1 Description of the indicator The downtime rate is the ratio of the downtime of production equipment to the total production time available for production equipment during the statistical period, and is an important indicator reflecting the health status of production equipment, maintenance quality and maintenance efficiency. 6.2.1.2 Calculation method Fault downtime rate calculation method see formula (13). 6.2.2 Average time between failures 6.2.2.1 Description of the indicator The mean time between failures is the average of the time between two adjacent failures of the production equipment during the statistical period. It is an indicator of the reliability of the production equipment and is used to evaluate the ability of the production equipment to maintain its function within a specified period of time. 6.2.2.2 Calculation method The calculation of the mean time between failures is shown in equation (14). 6.2.3 Average repair time 6.2.3.1 Description of the indicator The average repair time is the average of the time required between the occurrence of each breakdown and the completion of normal operation of the production equipment during the statistical period, and is used to evaluate the repair capability and speed of repair of the production equipment. 6.2.3.2 Calculation method The calculation of the average repair time is shown in equation (15). 6.2.4 Maintenance cost rate 6.2.4.1 Description of the indicator The maintenance cost rate is the ratio of the maintenance cost invested in the production equipment to the industrial output value obtained during the statistical period, and is an important indicator reflecting the quality level of production equipment operation and management. 6.2.4.2 Calculation method The calculation method of maintenance cost rate is shown in formula (16). 6.2.5 Spare parts inventory turnover rate 6.2.5.1 Description of the indicator The spare parts inventory turnover rate is the ratio of the spare parts consumption cost of production equipment to the average spare parts inventory capital in the statistical period, and is an important indicator reflecting the spare parts management capability of production equipment. 6.2.5.2 Calculation method The calculation method of spare parts inventory turnover ratio is shown in equation (17). 6.3 Energy and material indicators 6.3.1 Comprehensive energy consumption per unit of production value 6.3.1.1 Description of indicators The integrated energy consumption per unit of production value is the ratio of the integrated energy consumption of production equipment to its industrial output value during the statistical period, which is an important indicator reflecting the energy economic efficiency of production equipment. 7 General requirements for data collection of indicators Bibliography

Contents of GB/T 23023-2022

1 Scope 2 Normative references 3 Terms and definitions 4 Abbreviations 5 Classification of indicators 6 Description of indicators, calculation methods and improvement measures 7 General requirements for data collection of indicators Bibliography