scholarly journals Overall Equipment Effectiveness Improvement through Total Productive Maintenance in Assembly Cell

2013 ◽  
Vol 4 (1) ◽  
pp. 13-27 ◽  
Author(s):  
Napsiah Ismail ◽  
B. T. Hang Tuah Baharudin ◽  
Yusaini Musa ◽  
Zulkiflle Leman
Keyword(s):  
Lean Manufacturing ◽  
Assembly Line ◽  
Manufacturing Processes ◽  
Manufacturing Environment ◽  
Total Productive Maintenance ◽  
Established Method ◽  
Automotive Company ◽  
Assembly Cell ◽  
World Standard ◽  
And Performance

The Overall Equipment Effectiveness (OEE) is an established method to monitor and improve the effectiveness of manufacturing processes. OEE is frequently used as a key metric in Total Productive Maintenance (TPM) and Lean Manufacturing environment. This paper focuses on the OEE measurement of the assembly line of steering gear in an automotive company (AGR Sdn Bhd) through the implementation of TPM. The average OEE measurement before implementation of TPM is 52.21% which is below the company’s target. The company used reactive maintenance, which is inherently “wasteful and ineffective. After the implementation of TPM, the OEE performance for the assembly department improved to 70.21%. The result shows that machine down time directly influence the OEE. The implementation of TPM enables the company to change their maintenance practices from reactive to proactive. The average availability percentage is 80.34% and performance efficiency average is 87.99%. This has directly contributed to a lower overall OEE performance compared to world standard. The rate of quality is maintained at an average of 99.54%.

Process Improvement at Automotive Assembly Line Using Line Balancing and Lean Manufacturing Approach

2020 ◽  
Vol 899 ◽  
pp. 268-274
Author(s):  
Mohamad Hafizdudin bin Tajul Arifin ◽  
Wan Emri Wan Abdul Rahman
Keyword(s):  
Process Improvement ◽  
Automotive Industry ◽  
Manufacturing Process ◽  
Production Line ◽  
Lean Manufacturing ◽  
Assembly Line ◽  
Line Balancing ◽  
Automotive Company ◽  
Automotive Assembly ◽  
Current Production

The aim of this study is to analyze the existing production line in the automotive industry and proposed a layout of improved production line in the manufacturing process and obtain the optimum rate of production time. Thus, line balancing method and Yamazumi Chart was utilized to analyze the current and proposed production line. The collection of the data of the existing production line was conducted at one of the automotive company in Malaysia. From the analysis of current production line, two improved layout were proposed and evaluated. The proposed layout was selected based on a balanced production line and ability to meet customer demand. A balanced production line will ensure smooth process and eliminate wastage during operation

Implementation of Total Productive Maintenance Principles for Quality Improvement in an Automotive Company

2018 ◽  
Vol 880 ◽  
pp. 171-176 ◽  
Author(s):  
Cristina Ileana Pascu ◽  
Ilie Dumitru ◽  
Stefan Gheorghe ◽  
Mihai Nisipasu
Keyword(s):  
Quality Improvement ◽  
Production Process ◽  
Lean Manufacturing ◽  
Continuous Operation ◽  
Production Lines ◽  
Total Productive Maintenance ◽  
Automotive Company

In the automotive field, the application of Lean Manufacturing principles has become a common practice in recent decades. One of the basic methodologies of Lean philosophy is the Total Productive Maintenance (TPM). The TPM includes a number of methods initially designed to ensure the continuous operation of the machines involved in the production process so that production is never interrupted. In this paper some of the most important steps in quality improvement by implementation of TPM in an automotive company are presented. It is described the monthly implementation extent of TPM indicators starting from 2014 until now, especially on the production lines of the factory. Finally, the major benefits of TPM principles implementation in the company are highlighted.

Lean Manufacturing in Operations Management in Improving the Efficiency of Manufacturing Processes

2014 ◽  
Vol 945-949 ◽  
pp. 3117-3125
Author(s):  
Jaroslav Jambor
Keyword(s):  
Operations Management ◽  
Lean Manufacturing ◽  
Time Delays ◽  
Assembly Line ◽  
Efficiency Analysis ◽  
Production Costs ◽  
Labor Standards ◽  
Manufacturing Processes ◽  
Low Efficiency ◽  
Key Indicators

In this paper, we discussed the application of Lean Production for the application efficiency of the use of workstations on an assembly line in a car plant. The main objective is to increase the efficiency of labor, which is one of the key indicators of the competitiveness of the company and is directly related to its cost of production and cost of the final product. In this context, we compared the efficiency analysis of individual workstations on the assembly line and then select those whose efficiency was the lowest. It was carried out detailed analysis of all operations and operations that are performed on these selected stations. On this basis, we identified unproductive time delays causing low efficiency. They represent an opportunity to improve the production process in the form of adjustments to labor standards and workplace. The result of this work was to increase efficiency while repealing specific job position, which has resulted in savings in production costs.

Neue Fertigungssteuerung in der Ingenieurkeramik*/New approach to manufacturing control in engineering ceramics

2015 ◽  
Vol 105 (03) ◽  
pp. 109-114
Author(s):  
U. Bracht ◽  
F. Arzberger ◽  
F. Schulenburg
Keyword(s):  
Lean Manufacturing ◽  
Lean Production ◽  
Control Unit ◽  
Manufacturing Processes ◽  
Small Companies ◽  
Complex Environment ◽  
New Approach ◽  
Manufacturing Control ◽  
Volume Production ◽  
Low Volume

Auch kleinere Unternehmen mit komplexen Herstellungsprozessen müssen heute in der Kleinserie die Effizienz und Geschwindigkeit in der Produktion erhöhen. Zentraler Bestandteil ist dabei eine schlanke Fertigungssteuerung in einem ganzheitlichen Produktionssystem. Der Fachbeitrag zeigt, wie auch bei hoher Komplexität wesentliche Ansätze der „Lean Production“ genutzt werden, um die Produktion von Ingenieurkeramiken durch die intelligente Vernetzung bereichsspezifischer Methoden zu optimieren.   Today, even small companies with complex manufacturing processes in low-volume production have to improve efficiency and speed in manufacturing. A core aspect is lean manufacturing control within an overall production system. This article shows how the main approaches of Lean Production can be applied even to a highly complex environment. The intelligent integration of specific methods for each control unit helps to enhance the production of ceramics.

An Efficient Approach for Uncertain Event Detection in RFID Complex Event Processing

2021 ◽  
Vol 5 (4) ◽  
pp. 438
Author(s):  
Siti Salwani Binti Yaacob ◽  
Hairulnizam Bin Mahdin ◽  
Mohammed Saeed Jawad ◽  
Nayef Abdulwahab Mohammed Alduais ◽  
Akhilesh Kumar Sharma ◽  
...  
Keyword(s):  
Processing Time ◽  
Detection Algorithm ◽  
Manufacturing Processes ◽  
Memory Consumption ◽  
Production Flow ◽  
Manufacturing Environment ◽  
Thread Pool ◽  
Missing Items ◽  
Defensive Measures ◽  
Current Detection

The globalization of manufacturing has increased the risk of counterfeiting as the demand grows, the production flow increases, and the availability expands. The intensifying counterfeit issues causing a worriment to companies and putting lives at risk. Companies have ploughed a large amount of money into defensive measures, but their efforts have not slowed counterfeiters. In such complex manufacturing processes, decision-making and real-time reactions to uncertain situations throughout the production process are one way to exploit the challenges. Detecting uncertain conditions such as counterfeit and missing items in the manufacturing environment requires a specialized set of technologies to deal with a flow of continuously created data. In this paper, we propose an uncertain detection algorithm (UDA), an approach to detect uncertain events such as counterfeit and missing items in the RFID distributed system for a manufacturing environment. The proposed method is based on the hashing and thread pool technique to solve high memory consumption, long processing time and low event throughput in the current detection approaches. The experimental results show that the execution time of the proposed method is averagely reduced 22% in different tests, and our proposed method has better performance in processing time based on RFID event streams.

Hands-On Graduate Courses in Lean Manufacturing (LM) Emphasizing Green and Total Productive Maintenance (TPM)

2010 ◽  
Author(s):  
Geoffrey J. Peter
Keyword(s):  
Graduate Students ◽  
Case Studies ◽  
Lean Manufacturing ◽  
Building Design ◽  
Pilot Project ◽  
Design Stage ◽  
Total Productive Maintenance ◽  
Initial Product ◽  
Hands On ◽  
Institute Of Technology

The author developed and taught the second hands-on graduate course in a series of three Environmentally Friendly Manufacturing (EFM) courses offered at the Manufacturing and Mechanical Engineering and Technology (MMET) Masters Program at the Oregon Institute of Technology (OIT), Portland Center. Courses in this series include Environmentally Conscious Manufacturing (ECM-1), Lean Manufacturing (LM) emphasizing Green and Total Productive Maintenance (TPM), and Emission Control in Manufacturing (ECM-II). The first two-thirds of the course curriculum consisted of regular classroom lectures, limited homework, two case studies, discussions, videos, and visits to two companies that were implementing or had implemented LM. In addition, a guest lecturer from Washington State Department of Ecology discussed relevant LM and environmental case studies. The final third of the course curriculum consisted of hands-on industry-based case studies. Students gained real-world experience in the manufacturing facilities of the four companies that elected to participate in the pilot project. The LM course, taught from an engineer’s point of view, emphasized the engineer’s role at the initial product design stage, and or manufacturing process design, including building design. This paper describes the course content of the LM curriculum, the innovative methods developed to teach the course, and the methods used to teach LM to graduate students with different undergraduate educational backgrounds including individuals with no prior industrial experience. It discusses three industry-based case studies, company profiles, and the benefits derived by participating companies and graduate students. Curriculum effectiveness was determined at the end of the course in part through students’ and industry participant’s comments. Future publication will describe the contents and case studies of the third ECM II in the EFM course curricula.

scholarly journals Production flow improvement and value stream mapping in a lean manufacturing world

2021 ◽  
Vol 6 (1) ◽  
pp. 036-050
Author(s):  
Muhammad Adib Uz Zaman ◽  
Emad Rabiei Hosseinabad
Keyword(s):  
Lean Manufacturing ◽  
Performance Metrics ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Value Stream ◽  
Assembly Simulation ◽  
Kaizen Events ◽  
Load Leveling ◽  
And Performance ◽  
Flow Improvement

The importance of lean manufacturing concepts has been discussed many times over the few decades. The most important elements in lean manufacturing practices are value stream mapping (VSM), Kaizen events, load leveling (heijunka), etc. In this case study, a real-world clock assembly simulation has been used to study the performance improvement in terms of production flow and lead time after introducing lean concepts. In each round of simulation, the lean concepts have been introduced one by one and performance metrics were recorded. After implementing the concepts, the productivity was improved enormously. So, this simulation study emphasizes the importance of continuous improvement of production flow through lean concepts in a real production setting.

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