How to determine the equipment replacement rate. Shift coefficient, use of shift mode
The shift coefficient characterizes the efficiency of equipment use. It is calculated as the ratio of the total number of machine shifts worked to the amount of equipment in the enterprise (both used and all available). There is no established standard, but you need to strive for a value of 1, which indicates that the machines are fully loaded during the entire working time.
There are several indicators of economic analysis that characterize the efficiency of equipment use. One of them is the shift ratio. This indicator reflects the number of shifts worked by equipment during a certain time.
Calculation formula
The shift coefficient is calculated using the formula:
- C1, C2, Cn - number of machine shifts worked;
- N is the total number of machines (used or maximally usable).
You can calculate the indicator for different periods of time: day, week, decade, month, quarter, year. When calculating over long time intervals, one must take into account the fact that the composition of the equipment may change over time: some units are written off, others are put into operation. If there was some change in the number of machines at the enterprise, then it is worth calculating the coefficient for smaller periods, and then finding its average value for the required interval.
Reference! Machine shift is the time spent by any piece of equipment to produce a specified amount of work. This is the duration of use of the equipment for a limited time from starting the engine to stopping it (for example, 4, 8 or 12 hours). There can be several machine shifts in one machine day.
The duration of a machine shift is determined by the project, the nature of the work, the company’s field of activity, production volumes and other factors. This indicator can be calculated for companies in different industries that use any equipment in their work. However, most often it is used in relation to construction and industrial equipment (cranes, special vehicles, drilling rigs, excavators, etc.).
Calculation example
Known data for March 2018:
- 50 machines are installed in the workshop;
- 49 machines worked in the first shift, 30 in the second;
- working shifts per month - 20.
The calculation is presented in the table below (download in excel).
Thus, the shift ratio on the installed equipment is less, since there are 50 machines, i.e. 1 more than the operating ones. In fact, each machine worked 1.61 shifts.
- C - number of shifts.
The equipment was 79% occupied. More machines worked in the first shift, and in this case there will be more to the ISR:
The equipment was occupied 98% of the time.
On the second shift the situation is worse:
The machines only worked 60% of the time.
At this enterprise, you can increase the efficiency of equipment operation in the following ways:
- use more equipment on the second shift;
- reduce equipment downtime;
- expand the staff if downtime is due to labor shortages.
Interpretation of meaning
The shift ratio indicates the average number of shifts each machine worked. What conclusions can be drawn from the change in the coefficient over time, see the table below.
Decrease in CS |
|
---|---|
Increasing the efficiency of use of enterprise fixed assets | Decrease in efficiency of use of fixed assets |
Growth in production volumes | Reduction in production volume |
Expanding the area of machine use | Narrowing the area of equipment use |
Expanding staff responsibilities, combining professions, retraining | Reduced responsibilities for staff, everyone works on their own equipment, there is no combination of professions |
Getting rid of excess unnecessary equipment | The enterprise has a surplus of equipment not used in production |
The fact of partial use of equipment reduces the shift ratio. For example, in the workshop there is a machine that is needed for a couple of hours per shift. The rest of the time it is idle. However, it will not be possible to completely get rid of this piece of equipment: it is necessary for production. It cannot be transferred or downloaded in full. The operation of this equipment can hardly be called efficient, and it will also not be possible to completely transfer depreciation to the product. All this negatively affects the economic performance of the company.
Reasons for the low coefficient value
- Excess of inefficiently used resources.
- The predominance of outdated equipment that can be replaced with another, more efficient one.
- Dispersion of capacities at the enterprise, illogical organization of the production process, large losses of time when moving from one piece of equipment to another.
- Inconsistency between personnel and equipment, lack of knowledge and skills in operating machines.
- Negligent attitude of employees towards their duties, often caused by social factors (low wages, lack of medical care and food, difficult working conditions).
- Infrastructure deficiencies in cities and towns.
- Lack of conditions for equipment maintenance.
How to increase the coefficient value?
There are several ways to increase your shift ratio:
- reduction of downtime associated with the organization of workplaces;
- ensuring professional growth of employees, expanding their specialization;
- debugging the work process down to the smallest nuances, ensuring maximum speed and rhythm of work without loss of quality;
- timely updating and repair of equipment;
- competent organization of repair work;
- automation of manual labor.
Reference! You can increase the coefficient in a variety of ways. The main direction is to increase the efficiency of use of each piece of equipment, reduce downtime, and organize the smooth operation of the production line.
Standard
The higher the shift ratio, the more efficiently the equipment is used during working hours. We need to strive for an indicator equal to one (1). This will mean that the equipment is used for 100% of the entire shift length.
You can track the ratio over time, comparing it with indicators from previous periods. A decrease will indicate a negative trend, an increase - a positive one. If the coefficient is less than 0.5 and the enterprise operates in 2 shifts, then it is possible to transfer work to 1 shift and thus reduce costs and downtime. The shift ratio is just one of the indicators that allows you to evaluate the efficiency of equipment use along with
Indicators of the use of jobs are used when analyzing the use of labor in an enterprise. This group of indicators includes the following coefficients:
- shift ratio;
- shift utilization rate;
- continuity factor;
- integral coefficient of workplace utilization.
Shift rate characterizes how many shifts on average could be worked during the day if the shifts were evenly loaded with labor, i.e., provided that each shift employs as many people as work in the most crowded shift. This coefficient can be calculated both for a specific date and for a calendar period:
Characterizes the degree of uniformity in the distribution of workers across shifts. It is calculated as the ratio of the shift coefficient to the number of shifts of the enterprise according to the mode:
With an even load of shifts, the shift ratio will be equal to the number of shifts the enterprise operates, and the shift utilization rate will be equal to 100%. The more the shift utilization rate deviates from 100%, the less evenly workers are distributed across shifts.
Continuity coefficient or workplace utilization rate during the longest shift characterizes the use of workplaces in the busiest shift. This coefficient can also be calculated either for a specific date or for a calendar period:
Index
(number of man-days worked in the busiest shift) – (number of jobs * number of working days for the period)
characterizes the loss of working time in the busiest shift as a result of incomplete loading of workplaces.
Integral coefficient of workplace utilization gives a general description of the use of workplaces in all shifts. This coefficient can be calculated in two ways.
In enterprises and industries that operate in shift mode, shift indicators are also calculated, characterizing the use of shift mode, as well as the use of jobs available to the enterprise: shift ratio, shift utilization rate, workplace utilization rate in the longest shift and an integral indicator use of workplaces. These indicators are usually calculated for a category of workers on a certain date or for a calendar period.
Shift coefficient is the ratio of the number of man-days worked in all shifts to the number worked in the first shift.
Shift rate, calculated for a specific date is equal to:
When calculating the shift coefficient for a calendar period, it is equal to:
The shift mode utilization coefficient is defined as the ratio of the shift coefficient to the number of shifts under operating mode of enterprise C:
In the event that not all workplaces are used during the busiest shift, then the coefficient of utilization of workplaces on the busiest shift (K i.r.m) is calculated. When calculated on a specific date, it is determined by the formula:
When calculated for a calendar period, it is equal to:
The integral indicator of workplace utilization is defined as the product of the shift utilization coefficient by the workplace utilization coefficient in the longest shift:
End of work -
This topic belongs to the section:
Course project in statistics
Federal state budgetary.. educational institution.. higher professional education..
If you need additional material on this topic, or you did not find what you were looking for, we recommend using the search in our database of works:
What will we do with the received material:
If this material was useful to you, you can save it to your page on social networks:
Tweet |
All topics in this section:
Composition of working time funds. Working time balances
Working time is part of the calendar time spent on producing products or performing a certain amount of work or services; the length of time during which the employee
Working time balance
Time funds Use of working time 1. Calendar time fund 2. Holidays and weekends 3. Time fund
Indicators characterizing the use of working time fund
Based on balance sheet data, it is possible to calculate indicators of the use of time funds.
The coefficient of use of the maximum possible working time fund is equal to:
Average actual duration of working hours and working day
The working hours of employees are regulated by labor legislation, according to which the normal working week is 40 hours, and for minors and persons
Study of lost working time
The total loss of working time is determined on the basis of the working time balance as the difference between the time actually worked by all workers during the reporting period (excluding overtime hours) and
Indicators of the use of labor productivity levels
Enterprise personnel must not only have various abilities, but also use them in the work process. At the same time, there is a need to measure the performance of personnel, p
Natural, labor and cost methods for measuring the dynamics of labor productivity
The natural method of measuring labor productivity involves recording production in physical terms (in pieces, kilograms, meters, etc.). It is mainly used in enterprises
Example 1.1. Determine the shift ratios of installed and operating equipment.
At the enterprise, 15 machines worked in one shift, 20 machines - in two shifts, 40 machines - in three shifts, and 4 machines did not work at all.
Let's determine the replacement rate of installed equipment:
Let us determine the shift ratio of operating equipment:
Example 1.2. Determine the coefficient of extensive, intensive and integral use of the machine per shift.
Example 1.1. Determine the shift ratios of installed and operating equipment.
Shift duration - 8 hours.
The planned cost of repair work is 1 hour.
The actual operating time of the machine was 5 hours.
Machine output: according to the passport data - 100 products per hour, in fact - 80 products per hour.
1. To determine the coefficient of extensive use of equipment, it is necessary to determine the actual fund of machine time per day:
Thus, the planned machine fund is used by 71%.
2. Determine the coefficient of intensive use of the machine:
Thus, the equipment is used at 80% capacity.
3. The integral utilization factor of the machine will be:
Example 1.3. Determine the depreciation rate for fixed assets of a machine shop.
Example 1.1. Determine the shift ratios of installed and operating equipment.
The initial cost of fixed assets of the mechanical shop at the beginning of the year is 200 million rubles. On June 1, the milling machine, the initial cost of which was 2 million rubles, was taken out of service. For the year, depreciation charges for the workshop amounted to 23.86 million rubles.
1. Let us determine the average annual cost of fixed assets:
(million rubles).
2. Let’s determine the annual amount of depreciation:
Example 1.4. Determine the coefficients of extensive and intensive use of equipment, as well as the integral coefficient (in terms of time and productivity).
Example 1.1. Determine the shift ratios of installed and operating equipment.
At the enterprise, the duration of a work shift is 8 hours, with planned downtime for repair work of 1 hour. According to the passport data, the hourly productivity of the machine is 50 products. The actual operating time of the machine was 6 hours, 234 products were produced.
1. Let’s find the nominal operating time of the machine:
2. Determine the extensive load factor of the machine:
3. The maximum possible estimated number of products that can be produced will be:
4. Let's determine the intensive load factor:
5. Let’s find the integral coefficient of equipment utilization:
Topic 5. Working capital of the company: composition, classification, turnover.
1. Working capital: composition, classification and structure.
, (1.17)
where C 1, C 2, C 3 – the number of equipment operating in the first, second and third shifts, respectively;
C 0 – number of installed equipment.
Problem 2
Based on the work data of two enterprises, determine capital productivity, capital intensity and capital-labor ratio. Indicate which enterprise uses fire alarm systems better.
Solution
1. Capital productivity (production output per 1 UAH. OPS) is calculated according to formula (1.10):
;
for the 1st enterprise:
=
0,94 (
);
for 2nd:
=
1,67 (
).
![](https://i2.wp.com/studfiles.net/html/2706/821/html_uhzUKKMEA4.thGa/img-OMaxAu.png)
for the 1st enterprise:
=
1,07 (
);
for 2nd:
=
0,60 (
).
3. The capital-labor ratio is calculated using formula (1.11):
;
for the 1st enterprise:
=
37,73 (
);
for 2nd:
=
11,23 (
).
Conclusion : the technical equipment of the 1st enterprise is higher, but the operational security system of the 2nd is used more efficiently.
Problem 3
Determine the coefficient of extensive use of machine shop equipment. During the year, work was carried out in 2 shifts of 8 hours each. 5% of the nominal time was allocated for repairs. For various reasons, equipment downtime occurred for 159 hours. There are 366 days in a year, 113 days on holidays and weekends.
Solution
The coefficient of extensive use of equipment is determined by formula (1.14):
;
Calendar fund – the maximum possible operating time of the equipment.
Regime (nominal) fund – less than the calendar year by the number of weekends and holidays.
Real (effective) fund – less than nominal for the period of backup modernization.
Actual time worked – the sum of useful work time and the time of auxiliary and preparatory and final operations. This time is less than the actual (effective) fund by the amount of unforeseen downtime (malfunction and unscheduled repairs, adjustment and adjustment, lack of material, documentation, energy, workers, absenteeism).
F EF = F nom S (1-/100), where S is the number of equipment shifts; – percentage of lost working time for equipment repair;
F EF = (366-113) 8h 2cm (1-5/100) = 3845.6 (h);
F F = 3845.6 – 159 = 3686.6 (h);
K EC = 3686.6 / 3845.6 = 0.96.
Problem 4
Calculate the equipment utilization rate by productivity (intensive use rate). The average annual capacity of the enterprise is 3060 units. products. The actual operating time of the equipment is 3480 hours. The standard time for manufacturing a product is 1.5 hours, the percentage of standards fulfilled is 125%.
Solution
The coefficient of intensive use of equipment is determined by formula (1.15):
;
N POT = 3060 pcs.; PC.;
=
0,95.
Problem 5
Determine the shift ratio of the machine shop equipment if there are 200 machines installed in the workshop. During the reporting period there were 74 working days, duration 8 hours. A total of 188,300 machine hours were worked.