Optimizing OEE,productivity and production cost for improving sales volume in an automobile industry through TPM: a case study

The aim of this paper is to investigate how increase in sales volume has evolved by improving overall equipment effectiveness (OEE) of machines, plant productivity and production cost through total productive maintenance (TPM) initiatives in a reputed tractors manufacturing industry in India. In the present scenario of global competitive market, the manufacturing industry needs to improve their operational performance for surviving and prospering. TPM is practised by industry as a business tool for rapid and continuous improvement in its manufacturing capabilities. OEE offers a powerful control tool to overcome production deficiencies and operational performance constrains. Productivity and manufacturing cost are also crucial operational measures to analyse the manufacturing performance. In this study, evaluation and analysis of the methodology adopted for improving sales volume through TPM initiatives was carried out using an interactive research approach. The industrial example on the application of OEE tool demonstrates that it has a remarkable potential to enhance the equipment effectiveness. The empirical findings of the study reveal that augmented OEE and productivity, and reduced production cost resulted to double the sales revenue and triple the profit within a period of three years. The industry also achieved notably tangible and intangible benefits with the TPM implementation.     

Performance measurement using overall equipment effectiveness (OEE): literature review and practical application discussion

The quest for improving productivity in the current global competitive environment has led to a need for rigorously defined performance-measurement systems for manufacturing processes. In this paper, overall equipment effectiveness (OEE) is described as one such performance-measurement tool that measures different types of production losses and indicates areas of process improvement. Analysis is done on how OEE has evolved leading to other tools like total equipment effectiveness performance, production equipment effectiveness, overall factory effectiveness, overall plant effectiveness, and overall asset effectiveness. Two industrial examples of OEE application are discussed, and the differences between theory and practice analysed. Finally, a framework for classifying and measuring production losses for overall production effectiveness is proposed. The framework harmonizes the differences between theory and practice and makes possible the presentation of overall production/asset effectiveness that can be customized with the manufacturers needs to improve productivity.     

复合机铝箔换卷中的速度损失研究

目的减少铝箔复合机换卷时的速度降幅及变化,改善降速换卷中容易断幅的问题,从而提高设备的综合效率(OEE)。方法通过对实验数据的5W1H和张力分析,建立复合机铝箔换卷时铝箔张力的动力模型,探讨了张紧辊张力、压辊压力、铝箔偏心度、运动离心力方向角和速度差等影响铝箔张力的因素,并对实际操进行了实验改进。结果铝箔在换卷时速度变化得到改善,改善了断幅的问题。结论调整影响铝箔张力等一系列因素,综合效率(OEE)达到92.1%,提高了生产效率。     

AI设备综合效率分析与提升

设备综合效率（OEE）是评价当前设备的运行时间、运行速度、良品率、维修成本的一个综合指标,也是衡量生产活动中由设备创造的附加价值的尺度。对某电子产品生产企业AI设备综合效率进行了计算与分析,找出了导致其OEE低下的主要原因,并设计了AI设备综合效率提升方案,该设计方案的应用实施,使AI车间OEE水平达到目标水平,为稳定、高效的生产提供了支持和保障。     

Product line performance assessment on order fulfilment cycle time: a case of microelectronic communication company

The paper suggests data envelopment analysis (DEA) as a promising alternative technique to measure the relative efficiencies of production lines with several key performance indices. This study describes six key performance indices for a microwave communication company's order fulfilment process. We use four efficiency indices: global technical efficiency, pure technical efficiency, scale efficiency and mix efficiency to assess the performance of its nine production lines. The method is different from the traditional performance assessment and also considers the production line scale, management, operation and process.     

Classification and calculation of primary failure modes in bread production line

In this study, we describe the classification methodology over a 2-year period of the primary failure modes in categories based on failure data of bread production line. We estimate the probabilities of these categories applying the chi-square goodness of fit test, and we calculate their joint probabilities of mass function at workstation and line level. Then, we present numerical examples in order to predict the causes and frequencies of breakdowns for workstations and for the entire bread production line that will occur in the future. The methodology is meant to guide bread and bakery product manufacturers, improving the operation of the production lines. It can also be a useful tool to maintenance engineers, who wish to analyze and improve the reliability and efficiency of the manufacturing systems.     

Production line 3D visualization monitoring system design based on OpenGL

New production line management technologies are required and adopted recently with the development of modern manufacturing industry. In this study, a production line three-dimensional (3D) visualization monitoring system based on OpenGL modeling, open database connectivity (ODBC), and database management technology is established on a VC++6.0 platform to satisfy effective production. A client/server model is adopted in the system, and data on processing information, interactive operation, and failure process are stored in the server side database. A client reads the workpiece process information from the server, and the machining process of every workpiece is visually represented in the form of 3D visualization. Production line 3D visualization provides production capacity simulation to optimize the parameter settings. When compared with the analysis results of production line capacity, the key parameters possess the same optimal values, and this proves the accuracy of production line 3D visualization monitoring system. The system provides effective data support for production line monitoring and management in enterprises. The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0217-x     

Effect of maintenance policies on the just-in-time production system

Using simulation, experimental design, and regression analysis, mathematical models are developed here to describe the effect that maintenance policy, machine unreliability, processing time variability, ratio of preventive maintenance time to processing time, ratio of minimal repair time to preventive maintenance time, and production line size have on various measures of performance, namely total production line output and production line variability of the just-in-time production system. The analysis of the data shows that under different situations, different maintenance policies do not have the same effect on the production line performance. The following conclusions were obtained; when the number of production machines is low (five machines or less), and/or when the ratio of minimal repair time to preventive maintenance time is high, maintenance policy III leads to a higher performance than maintenance policy II. Otherwise maintenance policy II, which is more sensitive to the change of the ratio of minimal repair time to preventive maintenance time, leads to a higher performance. The results of the study can be utilized in choosing a maintenance policy as a function of the production process parameters. Once a policy is chosen, the practitioner can select the most important factors to control under that policy in order to minimize the machine idle time, maximize the production process reliability, improve productivity, and therefore increase the production line performance.     

卷包机组设备效率评价指标体系的设计与实现

目的 针对烟草行业常见设备卷包机组,提出一种结合OEE的设备效率评价体系,实现对卷包机组设备运行状态的精确、实时、具体的反映.方法 通过分析离散制造与连续制造的差异,在传统离散制造OEE方法基础上,针对连续生产进行适应性改进,提出一套针对卷包机组的设备效率评价指标;在此基础上,通过分析卷包机组各运行单元结构特点,提出一套实时采集设备状态数据与动态分析效率状态的卷包机组设备效率评价体系.结果 将此体系部署于湖北中烟某车间6台卷包机上6个月进行实验验证,结果显示在该体系的支持下,设备净效能平均同比增长7.72％,证明本效率评价结果可以精准、全面、实时地反映设备运行情况和状态背后的影响因素,有助于提升卷烟机组设备效率.结论 文中提出的卷包机组设备效率评价指标体系使用户可以针对性、快速地调整设备运行状态,实现了精准管理,提高了生产作业效率,具有实际的推广价值.     

基于RFID技术的运动器械包装生产线检验系统设计

目的针对传统人工方法进行运动器械生产线检验存在的缺点,设计一种用于运动器械出厂包装生产线的检验系统。方法将RFID射频技术、可视化软件和数据管理技术进行结合,利用RFID高效读写功能对生产线上输送的出厂器械进行有效的产品检验、产品管理和人员管理,以提升生产工厂智能化水平。结果经实际运行验证,该系统可自动完成40台器械产品的检验管理。结论所设计的检验系统运行稳定可靠,可以有效提升检验效率。     

制烧碱用阳离子交换膜的应用研究

介绍了5种离子膜N-90209、N-986、N-962、N-981、F-893的实验室性能．比较了它们在FM21型离子膜制碱电解槽上的运行情况，研究了它们的电压及电压上升速度，并就工业生产中离子膜的选择和使用进行了经济效益分析。结论为：N-981离子膜电压最低、耗电最小、N-962电压上升速度最慢、抗杂质能力最好；研究和选用合适的离子膜辅之予精心的生产管理，将会带来良好的经济效益。     

基于RFID和二维码技术应用的服装电商物流运作模式研究

服装是生活必需品,服装业是拉动国民经济增长的重要力量。本文应用RFID和二维码技术构建了两种增值服务模式：箱码（RFID）+单品（二维码）和箱码（二维码）+单品（二维码）,以期解决服装业存在的流通库存高、物流配送效率低及单品识别与回溯路径追踪难等难题。结果表明：将RFID和二维码技术应用于服装供应链电商物流,能够有效地提高服装供应链物流效率,加快库存流转;同时,也能够实现成本合适的服装单品识别、回溯路径追踪     

Developing performance measurement system for Internet of Things and smart factory environment

To cope with large fluctuations in the demand of a commodity, it is necessary for the manufacturing system to have rapid reactive ability. This requirement may be secured by performance measurement. Although manufacturing companies have used information systems to manage performance, there has been the difficulty of capturing real-time data to depict real situations. The recent development and application of the Internet of Things (IoT) has enabled the resolution of this problem. In demonstration of the functionality of IoT, we developed an IoT-based performance model consistent with the ISA-95 and ISO-22400 standards, which define manufacturing processes and performance indicator formulas. The development comprised three steps: (1) Selection of the Key Performance Indicators of the Overall Equipment Effectiveness (OEE), and the development of an IoT-based production performance model, (2) Implementation of the IoT-based architecture and performance measurement process using Business Process Modelling and (3) Validation of the proposed model through virtual factory simulation. We investigated the effect of the IoT-workability on the OEE, based on the final results of the simulation, both for the planned and actual productions. The simulation results showed that the proposed model represented the timestamp data acquired by IoT and captured the entire production process, thus enabling the determination of real-time performance indicators.     

Stochastic overall equipment effectiveness

This article focuses on the overall equipment effectiveness (OEE), a key performance indicator typically adopted to support Lean Manufacturing and Total Productive Maintenance. Unfortunately, being a deterministic metric, the OEE only provides a static representation of a process, but fails to capture the real variability of manufacturing performances. To take into account the stochastic nature of the OEE, an approximated procedure based on the application of the Central Limit Theorem is presented: the OEE is considered as a stochastic random variable and its probability density function (pdf) is generated through the aggregation of the pdf of the basic causes of waste. Notwithstanding its approximated nature, the procedure can be applied in most practical cases, since the accuracy is assured provided that the average OEE is lower than 90% and the variability of the losses is high. The validity of the approach has also been confirmed by an industrial application included in this article. The results obtained demonstrate that the stochastic OEE can help in battling variation, for it allows one to identify the hidden losses that account for most of the variability and to estimate the impacts of potential corrective actions in terms of both efficiency and efficacy.     

Labour productivity in modular assembly: a study of automotive module suppliers

Modular assembly is being applied to an increasing number of vehicles and part manufacturers to manage the ever-changing demands of the automotive industry. In spite of many researches performed on the supply chain management and logistics aspects of modular production, there is no research discussing modular production line concepts used by module suppliers. In this paper, labour productivity of two assembly line concepts including the conveyor line and box assembly line is studied under modular production environment. Both line concepts and respective assembly processes are described in detail. Mathematical models showing the total work faced by these two assembly line concepts are developed and compared. Two productivity scales are defined: the maximum achievable productivity and the actual productivity. The labour productivity rates of these assembly line concepts on above productivity scales obtained from calculations and a simulation are compared as a performance measure.     

基于RFID的药品生产管理及包装信息化

基于射频识别(RFID)的药品生产管理信息化需做到在药品整个生产周期及管理过程的可追溯性,可实现从药品原材料、生产过程、流通过程、销售过程,到消费者安全使用的全程信息化追溯。同时,药品的整个监管过程中也需信息化,并构建完善的药品监管溯源体系。基于RFID的钱夹式药品包装不仅给服用者以更灵活、理性的消费体验,还可通过终端连接制作厂商或药房医院,给消费者提供辨伪咨询等服务。药品生产管理及包装信息化模式虽然存在成本较高、应用平台整合难度大等问题,但其价值体现在能使高度复杂的数据共享成为现实,可帮助我国改善包装机械和制药行业打破"小而散"的行业态势,同时还能减少企业人工与管理成本,完善流通与销售监管,因此,具有较好的市场发展前景。     

Forecasting flow time in semiconductor manufacturing using knowledge discovery in databases

Semiconductor manufacturing is characterised by a complex production process, advanced equipment, and volatile demand. Flow time (FT), noted cycle time in semiconductor manufacturing, is a key measure in the operations. This study develops FT forecasting models using knowledge discovery in databases. It follows cross industry standards for data mining, with the focus on business understanding, data pre-processing and classification techniques. The data include wafer lot transactions extracted from the manufacturing execution system of an 8-inch flash memory factory. The FT is forecasted for a single lot at a given production step. The models are constructed using 70% of the data and the rest 30% for their evaluation. The results illustrate that a decision tree model achieves 76.7% accuracy and a neural network model 88.2%. The novelty of this work is in a thorough understanding of operations, a single data source, and common classification techniques used to obtain high accuracy results. The models can generate FT forecasting for a single production step, a line segment or a complete line. They can be used to improve short term planning, overall operations and supply chain efficiency, via shift scheduling, labour and materials requirements planning, inventory management and delivery schedules.     

啤酒包装线信息管理系统设计与开发

目的 针对啤酒生产企业的实际需求, 研究设计用于啤酒包装生产线管理的信息系统, 实时监控包装线运行状态, 对生产计划与执行情况进行动态管理。方法 采用SQL创建基础数据库, 以Eclipse为开发工具, 设计友好的人机交互界面。组建系统基本架构, 分析系统功能层次, 设计系统功能模块,即工厂建模、 生产数据管理、 数据综合展观等子模块, 采集存储包装线实时运行数据, 统计分析设备及整线的效率、 停机、 产量等生产信息。结果 该系统可实现基础数据的管理, 并能自动、 准确、 及时地追踪反馈包装线运行时各参数指标。结论 该系统对提高啤酒包装线效率、 减少生产损失具有良好作用, 是啤酒生产企业信息化管理的新趋势。