production - reducing machine setup time - iem
TRANSCRIPT
MACHINE PERFORMANCEBy Ir. Gan Chun Chet
MACHINE PERFORMANCE
• IMPROVING YOUR MACHINE PERFORMANCE BY KNOWING IT FIRST
• KNOWING THE CAPACITY TO PLAN AHEAD
MACHINE PERFORMANCE : RATIOS
• UNDERSTANDING THE RATIOS• RATIO OF PRODUCT CHANGE (To/Ts)
To = OPERATING TIMETs = SETUP TIME
• INDICATES THE OPERATING TIME OVER THE SETUP TIME
MACHINE PERFORMANCE : RATIOS
• RATIO OF NUMBER OF SETUPS AND PRODUCTS (Ts/Np)Ts = NUMBERS OF SETUPNp = NUMBER OF PRODUCTS
• INDICATES THE RATIO OF MACHINE SETUPS AND THE NUMBER OF PRODUCT PRODUCED BY THE MACHINE
MACHINE PERFORMANCE : PERFORMANCE INDICATOR
• MACHINE PERFORMANCE = (To/Tt) * 100PERFORMANCE OF THE MACHINE IN PERCENTAGE (%)
• OPERATING HOURS ToTo = Tt – (Ti + Tm + Ts)MACHINE TOTAL PRODUCTION HOURS TtMACHINE IDLE TIME TiMACHINE MAINTENANCE TIME TmMACHINE SETUP TIME Ts
MACHINE PERFORMANCE : PERFORMANCE VARIABLES
• MACHINE TOTAL PRODUCTION HOURS Tt (FIXED)TOTAL WORKING DAYS IN HOURS
• MACHINE IDLE TIME Ti (VARIABLE)NO PRODUCTION SCHEDULE
• MACHINE MAINTENANCE TIME Tm (VARIABLE)DEPENDING ON THE TYPE OF MAINTENANCE WORK
• MACHINE SETUP TIME Ts (REPETITIVE)MONITORING REQUIRED
MACHINE PERFORMANCE : MONITORING SETUP TIME – STATISTIC
• STATISTICAL TECHNIQUES• MAXIMUM SETUP TIME
THE MAXIMUM TIME OF THE SETUPS• MINIMUM SETUP TIME
THE MINIMUM TIME OF THE SETUPS• AVERAGE SETUP TIME• THE AVERAGE TIME OF THE SETUPS
MACHINE PERFORMANCE : MONITORING SETUP TIME – PREDICTION/FORECASTING
• PREDICTION TECHNIQUE• CATEGORY MODE OCCURRENCE
THE LOCATION OF THE MOST FREQUENT SETUP TIME• DEVIATION FROM ACTUAL BY MOVING AVERAGE
AVERAGE OF TWO ACTUAL PASTS CALCULATED WITH VARYING DEVIATIONDEVIATION FROM ACTUAL BY EXPONENTIAL SMOOTHINGTHE FRACTION OF ONE (1) GUESS OR PAST AND AN ACTUAL CURRENT WITH VARING DEVIATION
MACHINE PERFORMANCE : MONITORING SETUP TIME – PREDICTION/FORECASTING
• PROBABILITY OF UP OR DOWNTHE POSSIBILITIES OF EITHER AN UP, DOWN OR UNCHANGE COUNTED TO KNOW THE PROBABILITY
• ANGLE OF INCLINATIONTHE SLOPE OF EACH POINT MOVEMENT, WHETHER IS LOCATED AT VERY HIGH ANGLE, HIGH ANGLE, LOW ANGLE (NEGATIVE) OR A MODERATE LOW ANGLE
MACHINE PERFORMANCE : MONITORING SETUP TIME – DIAGNOSE THE REPETITIVE TASKS
• TWO TIME HIGH WITHIN THE LIMITSTWO TIMES THE SETUP TIME INCREASES WHETHER WITHIN AN UPPER LIMIT OR LOWER LIMIT WHICH IS A DEVIATION FROM A CHANGING MEAN TIME
• WARNING LEVELA PREDETERMINE SETPOINT TO WARN USER.
MACHINE PERFORMANCE : PERFORMANCE CHART
SIMULATION
Performance Chart
8800
9000
9200
9400
9600
9800
10000
10200
0 500 1000 1500
Setup Time (Ts)
Op
erat
ing
Ho
urs
(T
o)
Operating Hours(To=Tp-Ts)
Performance Chart
8800
9000
9200
9400
9600
9800
10000
0 20 40 60 80 100
Production Hours/ Setup Hours (Tp/Ts)O
per
atin
g H
ou
rs (
To
)
Ratio (Tp/Ts)
MACHINE PERFORMANCE : PERFORMANCE CHART
Ratio
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0 5 10 15
Number of Product
Set
up
/Pro
du
ct
Setup/Product 1
Setup/Product 2
Ratio
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
0 2 4 6 8 10 12
Number of Product
Op
erat
ing
/Pro
du
ct
Operating/Product 1
Operating/Product 2
SIMULATION
MACHINE PERFORMANCE : PERFORMANCE CHART
Operating Product
0
20
40
60
80
100
0 5 10 15
Number of Products
Op
erat
ing
Tim
e 10 Setups
20 Setups
30 Setups
• MORE SETUP, REDUCE OPERATING TIME
• NOTE RATIO OF PRODUCTION AND SETUP HOURS CHART
SIMULATION
MACHINE PERFORMANCE : PERFORMANCE CHART
Warning Level
14.0
18.5
11.410.8
18.9
11.3
15.8
3.1
15.0
12.4
15 15 15 15 15 15 15 15 15 15
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
20.0
0 2 4 6 8 10 12
Number of Setups
Tim
e (H
ou
rs)
Actual Time
Warning Level
SIMULATION
MACHINE PERFORMANCE : PERFORMANCE CHART
Distribution of Hours
87
3.4
7.62.3
0%
20%
40%
60%
80%
100%
1Machine
Pe
rce
nta
ge
(%
)
Percentage of Hours Spent OnSetups (Tsn/Ttn*100)
Percentage of Hours Spent OnMaintenance Time (Tmn/Ttn*100)
Percentage Machine Left Idle(Tin/Ttn*100)
Machine Performance (Ton/Ttn)
SIMULATION
MACHINE PERFORMANCE : PERFORMANCE CHART
Upper and Lower Limits
9.7
19.2
22.9
8.5
16.6
14.5 14.2
23.3
15.7
13.4
28.8
32.1
12.3
19.8
17.416.5
26.4
18.1
15.0
9.6
13.7
4.7
13.411.5 11.8
20.1
13.211.7
27.8
32.8
15.2
24.0
21.5 21.0
31.1
23.1
20.5
10.6
12.9
1.8
9.27.4 7.3
15.4
8.26.2
25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0
17.3 17.3 17.3 17.3 17.3 17.3 17.3 17.3 17.3 17.3
9.6 9.6 9.6 9.6 9.6 9.6 9.6 9.6 9.6 9.6
1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
32.8 32.8 32.8 32.8 32.8 32.8 32.8 32.8 32.8 32.8
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
0 2 4 6 8 10 12
Number of Setup
Tim
e
Actual Machine Setup Time
Upper Limit (Moving Average)
Low er Limit (Moving Average)
Upper Limit (Exp Smoothing)
Low er Limit (Exp Smoothing)
Category 1 \/
Category 1 /\ / 2 \/
Category 2 /\ / 3 \/
Category 3 /\ / 4 \/
Category 4 /\
MODE IN CATEGORY 3 IN THIS CASE
SIMULATION
MACHINE PERFORMANCE
• KNOW WHAT IS ACCEPTABLE• MONITOR TO SEE WHETHER IT IS LOCATED AT
YOUR MEAN PERFORMANCE• IDENTIFY THE IMPROVEMENT EITHER
POSSIBLE OF NOT
MACHINE PERFORMANCE
• STRATEGY• MORE OPERATION TIME• MORE SETUPS
• KNOW YOUR MEAN
MACHINE PERFORMANCE
• COST OF OPERATION• LINK TO TIME (POSSIBLE?)
• EXAMPLE:• REDUCE SETUP?• INCREASE FLEXIBILTY?
MACHINE PERFORMANCE
• KNOW YOUR MACHINE PERFORMANCE• KNOW YOUR MEAN PERFORMANCE• KNOW THE ESTIMATED PREDICTION
MACHINE PERFORMANCE
• KNOW THE CAPACITY• PLAN AHEAD
MACHINE PERFORMANCE
• EXCEL FILE – THE PURPOSE• ARTICLE – PREDICTIVE TECHNIQUE