Papers by Keyword: OEE

Abstract: Aircraft is still dominated by aluminum alloys despite the growth of composites and other lightweight materials due to their fatigue crack resistance, superior damage tolerance, and mature production methods. Assembly process of the aircraft's structures, must be involved for rivets and bolts, required a precise dimension compliance into the aviation guideline. Poor hole quality is one of the major challenges might cause cracks in the aircraft structure and reduce their reliability thus, manufacturing costs are directly affected by this rejection of parts at the assembly stage. The aim of this paper is to study on feed rate, towards surface roughness and Built Up Edges (BUE), and drilling of aluminium alloys used in aircraft component. An experimental approach was used to determine the most efficient feed rate for drilling operations. Observations were made on the BUE formation and roughness of the surface after each drill had completed up to 30 holes in order to meet the requirements of machined parts. From the experiment's findings, it was observed that the BUE formation and surface roughness both marginally changed as feed rates were varied. This experiment's most efficient feed rate was 0.15 m/min, and met the experiment's goal of determining the most efficient drilling feed rate. In conclusion, as feed rate increased, Ra (surface roughness) increased as well, while BUE decreased. While, Ra was set to a high feed rate, its value increased marginally. Drilling on aluminum alloy T6-6061 was accomplished at an efficient feed rate, resulting in improved product quality and reduced tool and workpiece damage.

Abstract: Overall Equipment Effectiveness (OEE) of a machine plays a significant role in the present scenario, where right quality and right delivery at the right time are the major factors influencing a customer. The aim of this article is to study the effectiveness and implementing of an independent maintenance system in a machine shop for enhancing OEE with the help of Total Productive Maintenance (TPM) and 5S techniques using a systematic approach. This has been focused to minimize the breakdowns, increase the performance and quality rate of machines so as to improve the effectiveness. During this research discussion, reviewing of documentation and sequential records and direct observations were used as data collection methods. In this case study, increase in efficiency and productivity of machines in terms of OEE by implementing TPM in a machine shop are discussed. This research work deals with the aspects of availability, performance and quality which are used to calculate the OEE of a machine. The TPM techniques such as 5S, preventive maintenance and cleaning were effectively applied on the machine. The final result showed that the OEE improved by 5% in horizontal machining center and by 7% in vertical machining center.

Abstract: The purpose of this paper is to present a method to quantify the costs of potential losses from production processes for new products to prioritize improvement projects based on the target cost and provide data and information for feasibility studies of continuous improvement projects. The specificity of the manufacturing cost policy deployment for new products is to identify the percentage of cost of future production phases which does not add value from a customer perspective, dynamically throughout the product life cycle. The percentage of non-value added cost is based on loss of each manufacturing process and is determined scientifically based on data and facts. Using the proposed method helps manufacturing companies in the acceptance of certain orders which at first glance are unprofitable. Moreover, the proposed method will help develop scenarios for continuous cost reduction after starting production through continuous improvement of productivity and quality required. The empirical results are based on the study during a year and a half in the automotive company, using action research methodology.

Abstract: Advanced cleanliness requirements in production are forcing industrial companies to include new cleaning processes into their manufacturing process. Complex cleaning operation procedures can lower process productivity and at the same time are responsible for substantial parts of the overall energy consumption. An optimization of cleaning processes with respect to cleaning duration, energy consumption and efficiency can therefore contribute to cost reduction significantly. This article presents a procedure for real data based assessment of industrial cleaning equipment. Based upon the resulting information of the procedure, productivity ratios and energy consumptions can be determined up to individual cleaning components. This creates the required transparency to derive customized production and energy efficiency optimization measures.

Abstract: The manufacturing industries have incredible contribution in the global economic growth and it has wide acknowledgment in the area of poverty mitigation. The manufacturing sector is also considered as one of the significant economic contributor in the Asian sub-continent for the past 100 years. Enhancement of productivity is an important factor for manufacturing industries to survive and to attain breakthroughs. By using time and motion study as tool, non-value added activities can be recognized and eliminated thereby productivity can be improved. Time and motion study is a tool to establish standard time for the processes including cycle time from observation with the allowance and rating factors. The main aim of the research is for systematic observation; process chart and stopwatch time study as research methodology. The article concludes that the successful application of motion and time study in industrial organizations is dependent on the training of the individuals who apply it. This article is also highlights enhancement of the Overall Equipment Efficiency (OEE) of the autoclave process through the implementation of time and motion studies.

Abstract: TPM is implemented in industry for improving production efficiency with an ultimate aim of attaining zero breakdowns, zero losses and zero defects. The purpose of this paper is to demonstrate the implementation of TPM initiatives and particularly the most contributing Kobestu-Kaizen (Focused improvement) Pillar in a process industry. The practical aspects and comprehensive approach for the deployment of Kobestu-Kaizen Pillar are presented as a case study. KK pillar helps to attain zero losses and to improve Overall Equipment Efficiency(OEE) of the processes and the plant. The benefits of TPM remained very encouraging and the company decided to continue with second phase of TPM implementation to achieve higher operational excellence.

Abstract: 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.

Abstract: Three different and complementary ways of adaptive control are presented, each working on a different time scale. All three of them are made possible due to evolutions and developments in CNC controls. The first and most popular way of adaptive control is adaptive process control. Since the process variables in sheet metal equipment change significantly in milliseconds, the control loop must also perform on a sub second time scale. The second adaptive loop is adaptive production control. Modern CNC controls know what they are manufacturing and talk with higher production software. Instead of just executing a planning that came top down, the CNC has enough knowledge of its environment that it can propose an intelligent job sequence and hence react more effectively on unforeseen situations. These adaptive loops perform on a time scale of hours and days. The third adaptive loop is adaptive resource control. To produce sheet metal parts, we need several kinds of resources: human resources, material, consumables, energy and equipment. CNC sheet metal equipment is a considerable investment. However most production managers do not know how effective their resources are being used. By applying the principles of overall equipment effectiveness, we can close the resource control loop. This loop performs on a time scale of weeks and months.