scholarly journals Evaluation of overall equipment effectivity in the cement manufacturing industry: a case study

2022 ◽  
Vol 1212 (1) ◽  
pp. 012048
Author(s):  
F Mustakim ◽  
H M Asih
Keyword(s):  
Preventive Maintenance ◽  
Surveillance System ◽  
Manufacturing Industry ◽  
Shop Floor ◽  
Root Cause ◽  
Fishbone Diagram ◽  
Cement Manufacturing

Abstract Overall equipment effectiveness is one of the important tools to measure the productivity in the company. This research is based on a case study of cement manufacturing industry in Indonesia, especially in kiln machine. The research aims to investigate the six big losses. In addition, the calculation of availability components, performance efficiency, and quality rate are carried out. The fishbone diagram is also employed to identify the root cause of the problem deeply. The results show the biggest losses in the kiln machine are the reduced speed losses. Therefore, the availability component and the performance efficiency should be improved to increase the productivity and the efficiency in the shop floor. Some suggestions are presented such as make a better surveillance system, improve the planning of preventive maintenance machine, and replace the more sophisticated maintenance tools to facilitate maintaining the machine.

scholarly journals Industrial Case Study on Lean Manufacturing Implemented on Manufacturing Polypropylene Ropes Industry Amravati

2021 ◽  
Vol 9 (12) ◽  
pp. 1318-1323
Author(s):  
Vipul Deshpande
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Developing Economies ◽  
Labour Productivity ◽  
Shop Floor ◽  
Industrial Case Study ◽  
Lean Principles ◽  
Manufacturing Techniques

Abstract: Lean manufacturing has been one of the most standard method in the manufacturing and service industry for elimination of waste. Every manufacturing industry has to put in continuous effort for its survival in the current impulsive and competitive economy. The purpose of this paper is to investigate the adoption of lean manufacturing tools and techniques in the manufacturing industries. This paper is based on actual implementation of lean manufacturing techniques. It focuses on the execution of flow from the start until the end of the implementation, types of analysis and tools applied, evaluation methods and how the industry benefited from the implementation. In this case study we particularly focused on Shop floor management, Quality Management (QM), Supplier and Customer Management (SCM) and Workforce Management (WM). After going through various testing on implementation of Lean Manufacturing principles in Micro Small medium Enterprise (MSME), researcher studied thoughts of some author where they discussed pragmatic problems they overcome while implementing lean principles in developing economies MSME. At the end, the result shows that there is monthly increment in capital productivity and labour productivity. And decrement in inhouse rejection, breakdown hours and customer complaint from the implementation of lean.

scholarly journals PERBAIKAN PADA FISHBONE DIAGRAM SEBAGAI ROOT CAUSE ANALYSIS TOOL

2013 ◽  
Vol 3 (3) ◽  
Author(s):  
Hari Agung Yuniarto ◽  
Annisa Dewi Akbari ◽  
Nur Aini Masruroh
Keyword(s):  
Bayesian Network ◽  
Root Cause Analysis ◽  
Quality Characteristics ◽  
Analysis Tool ◽  
Machine Method ◽  
Cause Analysis ◽  
Common Cause ◽  
Root Cause ◽  
Fishbone Diagram

<p>Diagram Fishbone (tulang ikan), atau biasa pula disebut ishikawa diagram ataupun cause effect<br />diagram, adalah salah satu dari root cause analysis tools yang paling populer di kalangan praktisi industri<br />untuk melakukan quality improvement mendasarkan pada usaha mengenali akar penyebab terjadinya variasi<br />pada quality characteristics tertentu yang ingin dicapai. Meski telah banyak dipakai di dunia industri,<br />disayangkan tool ini menderita kelemahan karena tidak memfasilitasi analisa korelasi antar potential root<br />causes dari masing-masing kategori yang ada (5M1E - man machine method measurement material<br />environment), selain tentu saja penyajian datanya yang hanya kualitatif. Kelemahan ini diyakini menjadi<br />kontributor utama penyebab kegagalan fishbone diagram dalam mengenali root causes yang berupa sumber<br />variasi common cause dan hanya mampu mengenali yang berasal dari sumber variasi special cause. Bertolak<br />belakang dengan karakteristik special cause variations, common cause variations adalah variasi yang terjadi<br />pada quality characteristics tertentu yang ingin dicapai di mana kemunculannya tidak mudah teridentifikasi<br />dan jikapun berhasil dikenali akan sulit dihilangkan karena sifatnya yang seolah adalah merupakan bagian<br />dari sistem (embedded in a system), cenderung berakar penyebab berupa soft factors serta kemunculannya yang<br />tidak random namun tersamar dalam pola tertentu.<br />Penelitian ini bertujuan melakukan improvement pada kelemahan yang terdapat di fishbone diagram<br />dengan mengadopsi kelebihan yang dimiliki oleh bayesian network agar mampu mengenali root causes yang<br />merupakan common cause variations. Kelebihan bayesian network mengatasi kekurangan fishbone diagram,<br />demikian pula sebaliknya. Oleh karena itu, analisa dilakukan terhadap fishbone diagram dan bayesian network<br />untuk mengenali characteristics dan kelebihan/kekurangannya. Hasil dari analisa tersebut mengarahkan pada<br />sifat-sifat komplementer dari keduanya yang diyakini mampu mengisi gap pada fishbone diagram.<br />Mendasarkan padanya, dikembangkan sebuah model untuk mengintegrasikan konsep serta sifat komplementer<br />yang dimiliki bayesian network dan fishbone diagram. Model ini merepresentasikan metodologi baru dalam<br />root cause analysis, bayes-fishbone. Metodologi yang dikembangkan ini kemudian diujikan ke sebuah case<br />study company untuk melihat applicability-nya.<br />Hasil dari penelitian ini menunjukkan bahwa metodologi bayes-fishbone yang dikembangkan terbukti<br />telah valid mampu merepresentasikan kondisi probabilitas produk cacat sebenarnya pada case study company<br />dengan prosentase perbedaan nilai yang ditunjukkan antara model yang dikembangkan dengan kondisi aktual<br />yang besarnya tidak signifikan yaitu kurang dari 1 % (0,9597%). Dengan menerapkan metode contructive<br />research approach, terbukti pula bahwa metodologi bayes-fishbone berhasil lolos weak-market test yang<br />menunjukkan bahwa metodologi yang dikembangkan applicable pada case study company atau perusahaan lain<br />yang sejenis characteristics dan production process-nya.</p>

Manufacturing excellence using lean systems – a case of an automotive aggregate manufacturing plant in India

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ravindra Ojha ◽  
Umashankar Venkatesh
Keyword(s):  
Project Management ◽  
Business School ◽  
Manufacturing Industry ◽  
Success Factors ◽  
Systems Approach ◽  
Real Life ◽  
Shop Floor ◽  
Content Type ◽  
Production Shop

PurposeThe paper aims at fulfilling two purposes: (1) to enrich young production shop floor managers to understand and appreciate the different dimensions of manufacturing excellence and (2) to provide a comprehensive industry-based case study to a faculty involved in the teaching-learning process of Lean systems to the Business school management students.Design/methodology/approachImparting learnings through a real-life case study from a manufacturing industry, which successfully doubled its delivery capacity using the project management and Lean systems approach. Value flow techniques have been utilised in the production shop floor.FindingsEffective implementation of lean thinking can significantly facilitate enhancing plant capacity within the original shop floor area and without hindering the delivery to the customers with growing demand. Outcomes of the plant transformation re-emphasised that effective leadership, a well-constituted project team, project management tools, applied knowledge of lean enablers and its metrics and management's engagement are the critical success factors.Research limitations/implicationsThe case has been automotive industry driven.Practical implicationsThis real life industry case study is expected to enrich not only the management graduates who would be industry leaders tomorrow but also the practising young shop floor managers who aspire to achieve manufacturing excellence through lean enablers and metrics.Originality/valueUseful real-life industry-based Lean manufacturing case study to be utilised by the business school faculty members in their class to enrich students/young practising managers.

Total Productive Maintenance - Accelerating OEE in a Manufacturing Industry Leveraging Pervasive Technologies

2011 ◽  
Vol 383-390 ◽  
pp. 4568-4575
Author(s):  
D. R. Kalbande ◽  
G. T. Thampi
Keyword(s):  
Preventive Maintenance ◽  
Manufacturing Industry ◽  
Zero Tolerance ◽  
Shop Floor ◽  
Total Productive Maintenance ◽  
Manufacturing Enterprises ◽  
Maintenance System ◽  
Start Up ◽  
Personal Process ◽  
Growth Prospects

Total productive maintenance (TPM) is a people-intensive, preventive maintenance system for maximizing equipment effectiveness in the enterprise. The concept of TPM was originally suggested by Nakajima (1988) who proposed overall equipment effectiveness (OEE) as a metric for evaluating the progress of TPM, which is interpreted as the multiplication of availability, performance and quality. This paper aims to study and investigate the implementation of a TPM to improve the OEE in manufacturing enterprises. In today’s industrial scenario huge losses occur in the manufacturing shop floor. These losses are due to operators, maintenance personal, process, tooling problems and non-availability of components in time etc. The quality related waste are of significant importance as they matter the company in terms of time, material and the hard earned reputation of the company. There are also other invisible losses like operating the machines below the rated speed, start up loss, break down of the machines and bottle necks in process. Zero oriented concepts such as zero tolerance for losses, defects, break down and zero accidents are becoming a pre-requisite in the manufacturing and assembly industry. In this situation, a TPM is the answer to resolve the above said problems which helps in benefitting the growth prospects of any organization.

scholarly journals Implementing total productive maintenance in a manufacturing small or medium-sized enterprise

2021 ◽  
Vol 14 (2) ◽  
pp. 152
Author(s):  
Zhang Tian Xiang ◽  
Chin Jeng Feng
Keyword(s):  
Action Research ◽  
Capital Investment ◽  
Manufacturing Industry ◽  
Production Efficiency ◽  
Model Development ◽  
Steering Committee ◽  
Shop Floor ◽  
Total Productive Maintenance ◽  
Active Involvement

Purpose: This paper develops a ‘light’ total productive maintenance (TPM) model suitable for small and medium-sized enterprises (SMEs). By design, the system is rudimentary, using a relatively small sum of capital investment and resources. The model recommends TPM implementation in three stages, namely plan, improve, and sustain.Design/methodology/approach: The literature review provides the inputs to the model development. Action research is used to demonstrate and verify the effectiveness and practicability of the framework, in an SME manufacturing hydraulic parts in China. Overall Equipment Effectiveness (OEE) and awareness of employees were studied before and after the implementation. Findings: The case study shows a significantly improved production efficiency of the equipment. The framework structuralizes TPM deployment and binding different levels of the organization into the program, from planning, implementation to sustaining the practices. To break the barrier of shop-floor resistance, the leader must drive many activities unassisted, it, therefore, necessitates an open endorsement of authority by the steering committee composed of top management. The Prudent pilot run of TPM helped to accelerate the implementation at critical equipment, in addition to cultivating experience and hence confidence among staff.Research limitations/implications: This study provides a pragmatic reference to other researchers and practitioners to promote a light TPM model in SMEs, without losing the essence of TPM. Being action research with the case study in a specific manufacturing industry, the resultant evidence, therefore, is anecdotal.Originality/value: The model adopts a phased method to implement TPM, without aggravating the financial and human resource burden of the enterprise. It promotes the cultivation of employees’ TPM awareness and active involvement, which can lay a solid foundation for the wide implementation of TPM in SMEs.

scholarly journals Measuring the Turnaround in Business Performance due to WMS and MES Implementation in a Process Manufacturing Client

2020 ◽  
Vol 5 (5) ◽  
Author(s):  
Sushant Siddharth Wanjari
Keyword(s):  
Business Performance ◽  
Manufacturing Industry ◽  
Positive Impact ◽  
Alcoholic Beverage ◽  
Shop Floor ◽  
Manufacturing Execution Systems ◽  
Maximum Benefit ◽  
Efficiency And Effectiveness ◽  
Process Manufacturing

The Warehouse Management System (WMS) and the Manufacturing Execution Systems (MES) have proven to be of massive help in increasing the organization’s productivity and its ability to execute key logistic functions with great efficiency and effectiveness. The process manufacturing industry has a unique setup and requires good collaboration between the different elements of the supply chain to operate at the highest efficiency. At the same time, the shop floor operators must have a good understanding of the new WMS/MES systems to derive maximum benefit from them. This paper dwells into the business improvements witnessed by an alcoholic beverage client after successfully implementing the WMS and MES solutions. The paper includes a literature review of the benefits and risks in WMS/MES implementation. Also, the literature is supported by a case study wherein the client’s business and operational challenges are discussed, and the improvements resulting from the project implementation. The WMS and MES were found to have a positive impact on business performance and it was observed that a project of such scale needs diligent planning and effective implementation for maximum benefits.

scholarly journals EVALUASI OVERALL EQUIPMENT EFFECTIVENESS SEBAGAI UPAYA PERBAIKAN PRODUKTIVITAS MESIN PRODUKSI KAIN NON-WOVENS (STUDI KASUS PT. MEGAH SEMBADA INDUSTRIES)

2020 ◽  
Vol 5 (2) ◽  
pp. 11
Author(s):  
Hartono Hartono ◽  
Aldi Pramana Putra ◽  
Tina Hernawati Suryatman
Keyword(s):  
Manufacturing Industry ◽  
Raw Materials ◽  
Poor Quality ◽  
Root Cause ◽  
Standard Product ◽  
Fishbone Diagram ◽  
World Class ◽  
Maintenance Schedules ◽  
Fabric Production ◽  
Resource System

The manufacturing industry has a system for applying machinery, labor, equipment and raw materials to be transformed into a product that has a sale value. Production machinery and equipment are the main resources that cannot be separated from the overall resource system owned by the company. At PT. Sumber Wovens Utama production machines are used nonstop and cause a decrease in performance of these machines which include frequent breakdowns, loss of ideal speed, and poor quality. The purpose of this study is to determine the overall value of the effectiveness of the production machinery at this time, to find the root cause of the overall equipment effectiveness value is not as expected, and to provide an improvement to the cause of the low value of the overall equipment effectiveness of the non-wovens fabric production machine. The method used in this research is the Overall Equipment Effectiveness Method to calculate the level of effectiveness and productivity of production machines, Fishbone Diagrams to solve problems in projects and Analysis of 5 why to provide improvements to the level of productivity of these machines. The results showed that the average overall equipment effectiveness value for the period November 2018 - April 2019 was 83.2%, this value was still below the world class standard of 85%. Therefore, it is given an improvement over the overall equipment effectiveness value not being achieved by making regular maintenance schedules for production machines, making standard product changeover procedures, making standard parameters for each type of product and updating it every 1 month, etc. so that it gets good results, namely increases the overall equipment effectiveness value of the production machine to be 88.30%.Keywords: Overall Equipment Effectiveness, Fishbone Diagram, 5 why analys, Mesin Produksi, Kain Non-wovens, Production Machine, Non-wovens Fabric

scholarly journals Effectiveness Improvement in Manufacturing Industry; Trilogy Study and Open Innovation Dynamics

2020 ◽  
Vol 7 (1) ◽  
pp. 7
Author(s):  
Ashwani Tayal ◽  
Nirmal Singh Kalsi ◽  
Munish Kumar Gupta ◽  
Danil Yurievich Pimenov ◽  
Murat Sarikaya ◽  
...  
Keyword(s):  
Manufacturing Industry ◽  
Shop Floor ◽  
Small Scale ◽  
Second Phase ◽  
Good Opportunity ◽  
Pareto Analysis ◽  
Innovation Dynamics ◽  
Fishbone Diagram ◽  
Small Medium Enterprises ◽  
Medium Enterprises

The purpose of this investigation is to compute overall equipment effectiveness (OEE) in the small-scale industry. The novel approach is introduced to detect bottlenecks by which OEE can be improved. This study attempts to help small-medium enterprises in analyzing performance in a better way. The automotive industry was chosen for conducting the research. The present study is comprised of three phases. In the first phase, OEE was computed and compared with world-class manufacturing. The second phase included three-level of Pareto analysis followed by making fishbone diagram to mitigate the losses. The third phase conducted improved OEE in the industry. There are seven major losses present in the industry that adversely affect the effectiveness of machine in any industry. This approach can reduce these losses and improve the quality, asset utilization (AU), OEE, total effective equipment performance (TEEP) and productivity of the machine. The study exposes that Pareto analysis uncovers all the losses and works on the principle of 80/20 rule. The major losses were thoroughly explored with the help of the fishbone diagram and solutions were implemented at the shop floor. As a result, availability, performance, quality, OEE, AU, and TEPP show improvements by 4.6%, 8.06%, 6.66%, 16.23%, 4.16%, and 14.58%, respectively. The approach offers a good opportunity for both researchers and small-medium enterprises around the world to analyze the indicators of production losses, performance, and productivity in the manufacturing industry.

scholarly journals Root Cause Assessment for a Manufacturing Industry: A Case Study

2013 ◽  
Vol 6 (1) ◽  
pp. 62-67 ◽  
Author(s):  
R. Kalantri ◽  
◽  
S. Chandrawat ◽  
Keyword(s):  
Manufacturing Industry ◽  
Root Cause
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