Production Equipment Productivity Analysis.
The choice of the machine. Replacement analysis. OEE analysis. Machine Work Study.
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Lesson 87 of Industrial Engineering ONLINE Course
Process Improvement - Productivity Analysis and Productivity Engineering.
Industrial engineer analyzes each process into its ultimate, simple elements, and compares each of these simplest steps or processes with an ideal or perfect condition and modifies the element appropriately. - F.W. Taylor - Hugo Diemer.
Prof. Hugo Diemer - Taylor's Industrial Engineering
https://nraoiekc.blogspot.com/2020/05/prof-hugo-diemer-taylors-industrial.html
Machine Productivity Analysis is part of facilities industrial engineering and process industrial engineering.
Question the choice of the machine for the operation in each process improvement study.
Do the replacement analysis is each facilities improvement study.
Do OEE analysis.
Part of Main Topic: Analysis of Items in Operation Information Sheet
1. Is there a better machine in the market available now?
2. Would the purchase of a better machine be justified?
Questions for Productivity Analysis related to Machine Tool being used.
Replacement Analysis Questions
1. Is there a better machine in the market available now?
2. Would the purchase of a better machine be justified?
3. Is there a better machine in the supply market now?
4. Is buy justified if the supplier is quoting a lower price?
5. Is there a retrofit available to improve the machines of the shop?
6. Is the retrofit justified?
7. What is the result of the replacement analysis for replacement by a similar machine?
Is it the best machine among the machines available in the shop?
1. Is the machine tool best suited to the performance of the operation of all tools available?
OEE Analysis
Availability - Speed - Quality
Are the machines being maintained adequately to assure availability?
Is the speed specified for machine is actually available for production?
Are the jobs utilizing maximum speed available on the machine?
Is the quality obtained from the machine satisfactory? Are any adjustments required to improve the quality?
Based on the questions, alternatives to improve the operation in the area of of machine tool being used can be determined and evaluated for the additional productivity opportunity.
Machine Tool Productivity Engineering Related Information
New Machine Tools - Productivity Engineering Applications
Analyze for Presence of These Losses
A. Seven major losses that impede overall equipment efficiency
1 Failure losses (Breakdown) Losses due to failures.
Types of failures include sporadic function-stopping failures, and function-reduction failures in which the function of the equipment drops below normal levels.
2 Set up and adjustment losses
Stoppage losses that accompany set-up changeovers
3 Cutting blade change losses
Stoppage losses caused by changing the cutting blade due to breakage, or caused by changing the cutting blade when the service life of the grinding stone, cutter or bite has been reached.
4 Start-up losses
When starting production, the losses that arise until equipment start-up, running-in and production processing conditions stabilize.
5 Minor stoppage and idling losses
Losses that occur when the equipment temporarily stops or idles due to sensor actuation or jamming of the work. The equipment will operate normally through simple measures (removal of the work and resetting).
6 Speed losses
Losses due to actual operating speed falling below the designed speed of the equipment.
7 Defect & rework loss
Losses due to defects & reworking
B. Losses that impede equipment loading time
8 Shutdown (SD) losses
Losses that arise from planned equipment stoppages at the production planning level in order to perform periodic inspection and statutory inspection
C Three major losses that impede efficient use of production subsidiary resources
9 Energy losses
Losses due to ineffective utilization of input energy (electric, gas, fuel oil, etc) in processing.
10 Die, jig and tool losses
Financial losses (expenses incurred in production, regarding renitriding, etc.) which occur with production or repairs of dies, jigs and tolls due to aging beyond services life or breakage.
11 Yield losses
Material losses due to differences in the weight of the input materials and the weight of the quality products
Manufacturing System Losses Identified in TPM Literature - Principles of Machine Economy
It is interesting to note that a book has 4 chapters discussing equipment efficiency.
Improving Production with Lean Thinking - Javier Santos, Richard A. Wysk, Jose M. Torres
Uniqueness of the book - Equipment efficiency is discussed in 4 chapters in this book.
John Wiley, 2014, Google book with preview facility
Chapter 4. Equipment Efficiency: Quality and Poka-Yoke.
Introduction.
Theoretical Bases.
Inspection and SQC (Statistical Quality Control).
From SQC to Zero defects.
Poka-Yoke design methodology.
Poka-Yoke examples.
Summary.
Recommended Readings.
Chapter 5. Equipment Efficiency: Performance and Motion study.
Introduction.
Theoretical Bases.
Motion economy principles.
Motion study tools.
Value analysis.
5W2H and 5-Why methods.
Worker-machine diagram.
Machine-worker ratio.
Machine-machine diagram.
Summary.
Recommended Readings.
Chapter 6. Equipment Efficiency: Availability, performance and maintenance.
Introduction.
Theoretical Bases.
Types of maintenance.
Maintenance program implementation.
Getting started.
Corrective maintenance implementation.
Preventive maintenance implementation.
Autonomous maintenance.
TPM - Total Productive Maintenance.
RCM - Reliability Centered Maintenance.
Maintenance tools.
FMEA for equipment.
Reliability.
P-M Analysis.
Maintenance management.
Summary.
Recommended Readings.
Chapter 7. Equipment Efficiency: SMED.
Introduction.
Theoretical Bases.
Basic steps in a set-up process.
Traditional strategies to improve the set-up process.
SMED methodology.
Preliminary stage.
Stage 1. Separating internal and external set-up.
Stage 2. Converting internal set-up to external set-up.
Stage 3. Streamlining all aspects of the set-up process.
SMED tools.
First stage tools.
Second stage tools.
Third stage tools.
Zero changeover.
SMED effects and benefits.
Easier set-up process.
On-hand stock production.
Workplace tasks simplification.
Productivity and flexibility.
Economic benefits.
Summary.
Recommended Readings.
Improving Production with Lean Thinking - Santos, Wysk, Torres
The above four chapters provide us the directions for equipment productivity analysis.
Ud. 26.8.2024, 27.8.2023, 26.8.2022
Pub. 16.9.2020
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