CSECS05
CSECS05
Abstract: - Efficiency of industrial production lines is crucial as it results in an improved production and
utilization of available resources. Factors contributing to production line efficiency are manpower utilization
and machine efficiency. Measuring the machine efficiency and man power utilization should be on-line,
accurate and truthful. The management should be able to look for relevant production data and to accurately
interpret these data in order to identify the various faults at production level and to immediately take steps to
improve efficiency. However, faults are overwritten and reports are retouched with inaccurate information. An
accurate and on line data management system can ensure that these problems are overcome.
Key-Words: - Machine efficiency, man power utilization, industrial production line, data management system.
1 Production system in industries output. Thus, such process lines demand expert and
professional people in designing and maintaining the
A production line is a set of sequential process system.
established on an industrial shop floor. A
production process or a manufacturing process is the
transformation of raw materials or components into 2 Production line inefficiency
finished products. The stages in a production
process involve procurement, fabrication, assembly,
testing, packaging and distribution. The production Production line
or manufacturing lines in industries can be
categories into three type’s i.e. automated
production lines, semi-automated production lines
and manual production lines.The nature of a
production line depends on the complexity of the
manufacturing parts, the production volume, the Machine efficiency Man power utilization
sensitivity of the product and cost. Industries’
Supporting Operator /
management plan and layout their production lines department workers
according to specific production requirements.
Machine efficiency is one of the factors that are Human performance varies from time to time
frequently overlooked by the management and this depending on their capability and duration of work.
can lead towards losses which reduces the yield [1], When the performance of a worker drops, the
[2]. Improper maintenance of machines will result in production output also drops. Improper monitoring
low standards of produced parts and increases the of workers will result in low standards of production
maintenance of machines. Machines are meant to output and will increase the maintenance of
work efficiently, but in some circumstances machineries. The major factor contributing to this is
machines can be less productive due to improper the attitude of the workers themselves. Most of the
preventive maintenance. Preventive maintenance is a workers tend to perform in an average manner and
key factor that keeps the machine running efficiently for most of the time they will be less productivity
through the production process. The maintenance and this will result towards wastage of the planned
activity on machines needs extra attention by the production time [3].
management along with the responsible personnel to
ensure optimum usage of machineries which will
eliminate unwanted wastages due to machine 3 Production breakdown
stoppages.
Some industries operate in two 12 hours shifts or
2.2 Manpower utilization operate in three 8 hours shifts a day. The planned
shift length can be divided into two, which is the
Humans play a major role on the industrial shop Planned Downtime and Planned Operation Time.
floor especially when it comes to meeting targets. Planned downtime is a duration of time where the
Humans in the production floor can be divided into management has decided to stop the production
two categories which are workers or operators on the process due to certain commitments such as
production line and the workers in the supporting preventive maintenances, improvement projects, low
department. in production order and etc. Planned operation time
is the proposed time for production process by the
2.2.1 Supporting department management. Generally the planned operation time
can be divided into two which is actual operation
Humans capitalize most of the process on time and unplanned downtime. Both these factors
industries from the management to the layman are the major concern for the management when it
(operators). An industrial environment is one in comes to measuring machine efficiency and man
which there are a large number of people from power utilization. Industries try to maximize the
various departments working together to meet set actual operation time and minimize the unplanned
goals. When it comes to unmet goals, fingers should downtime to improve their capacity in all means [4].
also be pointed to the supporting department as they The production duration can be categorized as
also contribute to this matter. The supporting shown in fig. 2.
departments play their role in maintaining the
consistent pace of work on the industrial shop floor. Planned Shift Length
4.4 Overall Equipment Effectiveness restricted word in industries because they will lead
towards cost factor. Rejection can be categorized
Availability, performance and quality combined into two which is reject rework and this usually falls
into one OEE score and this single number provides on parts that can’t be repaired to maintain base on
a complete measure of machine efficiency. OEE is the customer’s specification. The second reject is
the ratio of actual production time to planned reject scrap which is total lost part and these parts
production time. OEE is calculated as in (4) [2], [4], are waste materials. Such facts will affect the output
[7], [12] - [13]. when it comes to tight end.
OEE = Availability x Performance x Quality (4) The PPC involves in planning the production
process and supplies base on orders. When parts are
not ordered base on demand then the production
5 Measuring man power utilization process will be effected when the raw parts are
running short. The most crucial task of this
Sufficient production data is used in assisting department is to plan the production process base on
operators especially in informing operator of their daily targets. Wise production line management is
performance to date. Apart from that the data will important for this team to sustain.
also be able to guide the operator to maintain a
consistent pace throughout the day and this will The maintenance department is responsible for
result in a better implementation of work morale all technical matters on the industrial shop floor.
among the employees. Once the operators have been Preventive maintenance is the important task for this
tuned to react according to the management’s set department whereby the machine has to be checked
goals, this will automatically eliminate wasted time on timely basis to ensure optimum performance of
and hence produce more units per hour. the machines. This is to reduce machine parts
replacements. Apart from that the most critical
Essentially human capitalize nearly all the matter on industries is safety. When a machine is out
process on the industrial shop floor from the of shape, the higher chances for the human who
management to the layman (operators). Visualizing operates it will be injured.
an industrial environment which includes a big
number of people from various departments working 5.1 Operators or workers utilization
together in meeting the set goals. When it comes to
unmet goals, fingers are not to be pointed to an Operators or workers utilization falls under man
individual, whereby the supporting department also power utilization which includes any factors that
has their contribution on this matter. Monitoring of cause the production process to operate at less then
supporting departments in industries is another the maximum possible speed base on the time study
factor which should be taken in account for or cycle time. The major factor on measuring the
improving the production performance. By knowing performance of human workers is the operator’s
their performance, the departments can be aware of inefficiency. Base on fig 6 the man power utilization
the problems arising and counter measures can be is measured from the duration of actual operation
taken to further improve their working quality. The time. For manual process lines, man power
supporting departments play an equal role as the utilization is the ratio of actual production output to
production team in order to maintain the consistence target production output as in (5).
pace of work on the industrial shop floor. There are
three basic departments in industries which are the Man Power Actual Production Output (5)
=
total quality management (TQM), production Utilization Target Production Output
planning and control (PPC), maintenance and adding
to that is others (vendors) also is added to the list as For semi automated process lines, man power
one of the major contribution on production utilization is slightly different from (5) where by the
interruption. operators ideal cycle time is the minimum cycle time
that the process can be expected to achieve under
The TQM involves all the quality matters of the optimal conditions for a given process. This is due to
parts produced. When a machine is not calibrated the combination of humans and machine to perform
base on specification or irregular inspection on the a specific task on the same work station. Man power
parts produced it will result in higher rate of utilization should be separated from the machine
rejection or parts near to perfect. Rejection is a
performance for easy analysis. Therefore when it is OEE Factor Actual OEE Target OEE
multiplied by total pieces produced the result is
actual operation time. Man power utilization for Availability 83.96 % 85.00 %
semi automated process lines is calculated as in (6). Performance 42.70 % 90.00 %
Quality 57.89 % 95.00 %
(Operators Ideal Cycle Time x (6)
Total Pieces Produced) Overall OEE 20.75 % 73.00 %
Man Power
= Actual Operation Time –
Utilization
(Machine Ideal Cycle Time x Table 1 Data on machine overall efficiency
Total Pieces Produced)
6.2 Data on man power
5.2 Performance of supporting department
Table 2 shows the actual performance of the
Supporting departments in industrial are divided operator on a certain shift is 22.35%. Based on this,
into 3 basic departments and the performance should the management could optimize their human capital.
be measured individually before analyses are carried From the data collected in table 2, the management
out. Performance of the supporting department is can easily trace the major contributor for unmet
calculated as in (7) where by the down time for a targets. The management can also differentiate table
specific department is subtracted from planned 1 with table 2 for more details analysis to identify
operation time and divided by planned operation the root cause of the unmet targets.
time. This formula is a common formula for all
Factor Calculated Data Performance
types of process lines in industries.
Man Power (19 x 3) / 445
= 22.35 %
Utilization - (19 x 10)
(Planned Operation Time
Performance of – Down Time) (7)
=
Supporting Department Table 2 Data on man power utilization
Planned Operation Time
After analyzing each factors, the process line [2] Daniel Sheu D., “Overall Input Efficiency and Total
operator is clearly the major contributor towards the Equipment Efficiency”.
unmet target. The second crucial factor is the IEEE Transactions on Semiconductor Manufacturing
machine on the process line which is far below the 2006,
19: 496-501.
bench mark set by the management on each factors
[3] Siva Kumar a/l Subramaniam, Siti Huzaimah binti
under OEE which also contributes towards the Husin, Yusmarnita binti Yusop and Abdul Hamid bin
unmet target. The rejection rate of the parts Hamidon, “The production performance monitoring
produced is also high and this indicates that the system”.
machine on the work station is not properly The 6th WSEAS International Conference on Circuits,
calibrated or the standard operating procedure (SOP) Systems, Electronics, Control & Signal Processing
is not complied by the operator. (CSECS’07) World Scientific and Engineering
Academy and Society, 29-31 December 2007,
Understanding each of these factors helps the pp 185-190.
management to improve factors affecting unmet [4] Tom Pherson, “Overall Equipment Effectiveness &
Real-Time Visual Management Critical Lean Tools”.
targets. Such data should also assist management in
Intelligent Manufacturing Solutions June 2006,
optimizing their usage of man power and machines Page(s):1-18
efficiently. Actions should be taken to remedy the [5] Philip Godfrey, “Overall equipment effectiveness”
faults of each section in order to meet a better target IEEE Transactions on Semiconductor Manufacturing
and yield. 2002,
Volume 18, Issue 1, Page(s): 190 – 196
[6] David Drickhamer, "IW Census targets key
manufacturing metrics".
7 Conclusion Industry Week Magazine 2001, Issue November 1.
[7] Ziemerink, R.A. & Bodenstein, C.P., “Utilising a Lon
Relevant and valuable production data helps the Works control network for factory communication to
management to efficiently monitor the workers. improve overall equipment effectiveness”.
Information on human capital can optimize the true IEEE International Symposium on Industrial
capacity of the workers performance. The awareness Electronics Proceedings ISIE '98,
of OEE is essential for industries when it comes to Volume 2, 7-10 July 1998 Page(s): IEEE International
decision making. The simple metrics of the OEE Symposium 684 - 689
brings to light all the valuable information required [8] Killeen, D., Gaboury, P. & Paccard, D., “Managing,
by the management. The Production data should be measuring and improving equipment capacity and
overall equipment efficiency (OEE) using iPLUS”.
very well interpreted and fully utilized in order to
2001 IEEE International Semiconductor
optimize available resources within the industrial Manufacturing Symposium, 8-10 Oct 2001,
sector. This will reduce wastage and increase the Page(s): 25 – 28
production yield. By taking these necessary steps [9] Freck, R.W., “Using Overall Equipment
industries can improve and maintain more efficient Effectiveness (OEE) and The Equipment
production lines. Improvement Process (ET) to Improve Fab
Throughput”
IEEE/SEMI Advanced Semiconductor Manufacturing
Conference and Workshop,12-14 Sept. 2000
8 Acknowledgement Page(s): 469 – 471
[10] Simon Bragg, "Implementing OEE".
The author would like to thank Oriental Summit ARC Insights, Insight#2003-07E,
Industries TM Sdn. Bhd. for their support in ARC Advisory Group,
supplying various technical and production Issue February 12.
information for this research. [11] Vorne Industries Inc., July. 9, 2007
URL: http://www.vorne.com/pdf/fast-guide-to-
oee.pdf
References: [12] Productivity Dev Team, “OEE for operators: Overall
[1] Konopka J. and Trybula W., “Overall equipment Equipment Effectiveness”
effectiveness (OEE) and cost measurement Productivity Press. July 1999,
semiconductor manufacturing”. Page(s): 4-7
Nineteenth IEEE/CPMT Electronics Manufacturing [13] Robert C.Hansen, “Overall Equipment
Technology Symposium, 14-16 Oct. 1996 Effectiveness”. First edition
pp 137-140. Industrial Press, December 2001,
Page(s): 1-20