Upload
shrikantha-hs
View
221
Download
0
Embed Size (px)
Citation preview
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
1/27
AA systemicsystemic Strategy forStrategy foroptimizing manufacturingoptimizing manufacturing
operationsoperations
Presented ByPresented By
HANUMANTHARAJU .LHANUMANTHARAJU .L
1BM05IM0151BM05IM015
dept. of IEM,dept. of IEM,
BMSCEBMSCE
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
2/27
Optimizing the ManufacturingOptimizing the Manufacturing
ProcessProcess IntroductionIntroduction
Definition of marketing excellenceDefinition of marketing excellence
Five basic Objectives of ManufacturingFive basic Objectives of ManufacturingExcellenceExcellence
1.Match through out1.Match through out with demandwith demand
2.Reduce2.Reduce inventoryinventory
3.Maintain3.Maintain high qualityhigh quality through outthrough out thethe
operationoperation
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
3/27
Objectives of manufacturingObjectives of manufacturing
excellenceexcellence4.Reduce4.Reduce lead timeslead times
5.Reduce5.Reduce operating expensesoperating expenses
Strategy for improvement opportunitiesStrategy for improvement opportunities
Asset Utilization (AU)Asset Utilization (AU)
Optimization frameworkOptimization framework
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
4/27
Polymer sheet formationPolymer sheet formation
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
5/27
Polymer sheet formationPolymer sheet formation
Taken as a case studyTaken as a case study
Teams of improvement activitiesTeams of improvement activities
Method of formation of the polymer sheetMethod of formation of the polymer sheet
The teams consists of engineers, workingThe teams consists of engineers, working
people within the polymer operationpeople within the polymer operation
Manufacturing process is an art and not aManufacturing process is an art and not asciencescience
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
6/27
Asset Utilization (AU)Asset Utilization (AU)
Process for identifying and quantifyingProcess for identifying and quantifying
opportunities for improvementopportunities for improvement
Goal not to have 100% AUGoal not to have 100% AU Key manufacturing productivity parametersKey manufacturing productivity parameters
%Availability, %Run time efficiency, %Run%Availability, %Run time efficiency, %Run
speed efficiency, %yieldspeed efficiency, %yield
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
7/27
Productivity parametersProductivity parameters
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
8/27
AU definitionsAU definitions
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
9/27
Guide lines for AU implementationGuide lines for AU implementation
Guide lines for implementing AssetGuide lines for implementing Asset
UtilizationUtilization
3 main guidelines3 main guidelines
Drive towards predictable equipmentDrive towards predictable equipment
Focus on increasing AU of capacityFocus on increasing AU of capacity
constrained equipmentconstrained equipment Not to drive AU to 100%Not to drive AU to 100%
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
10/27
Process Optimization FrameworkProcess Optimization Framework
To increase productTo increase product qualityquality
it Consistsit Consists of two partsof two parts Three parallel activitiesThree parallel activities
Examines the cause and effect relationshipExamines the cause and effect relationship
b/wb/w casting process conditions and resultingcasting process conditions and resulting
sheetsheet productproduct attributesattributes
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
11/27
Flow diagram of casting processFlow diagram of casting process
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
12/27
Parallel activities of optimizationParallel activities of optimization
frameworkframework
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
13/27
Results and DiscussionsResults and Discussions
AU analysis for a set of polymer m/csAU analysis for a set of polymer m/cs
MostMost of the downtimeof the downtime due to unscheduleddue to unscheduled
maintenancemaintenance m/cs were run at lower speeds instead ofm/cs were run at lower speeds instead of
higherhigher speedsspeeds
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
14/27
M/cM/c AvailaAvaila
bilitybility
RunRun
timetimeeffcy,%effcy,%
RunRun
speedspeedeffcy,%effcy,%
Yield,Yield,
%%
AU,%AU,%
CC 7878 9696 7575 6868 3838
DD 9595 9999 8888 8080 6666
FF 6464 9595 7474 6969 3131
GG 9595 9898 8484 8585 6666
HH 8181 9696 9191 7272 5151II 9393 9898 8585 7979 6161
MM 8686 9797 8585 8181 5757
OO 9797 9999 7979 8585 6464
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
15/27
Process Optimization FrameworkProcess Optimization Framework
Knowledge and experienceKnowledge and experience
Most common undesirable conditionMost common undesirable condition--
widthwise thickness variabilitywidthwise thickness variability Main techniqueMain technique-- fault tree diagramsfault tree diagrams
Brainstorming sessionsBrainstorming sessions
Process by which these diagrams areProcess by which these diagrams aregenerated are important for capturinggenerated are important for capturingknowledge opinions of the experiencedknowledge opinions of the experiencedpersonnelpersonnel
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
16/27
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
17/27
Second activitySecond activity
Statistical ToolsStatistical Tools
Goal of this second parallel activity is toGoal of this second parallel activity is to
obtain a predictive modelobtain a predictive model These are made from the preThese are made from the pre--existing dataexisting data
inputs the prediction models are then testedinputs the prediction models are then tested
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
18/27
Third ActivityThird Activity
OrderOf Magnitude TheoreticalOrderOf Magnitude Theoretical
CalculationsCalculations
Used to examine the effects of changingUsed to examine the effects of changingpolymer temperature and viscosity.polymer temperature and viscosity.
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
19/27
Designed screening experimentDesigned screening experiment
Experiment designed to examine the castingExperiment designed to examine the casting
processprocess--sheet thickness profile relationshipssheet thickness profile relationships
to verify the casting functions, distribute flowto verify the casting functions, distribute flowshape catenaryshape catenary
limited use of this methodlimited use of this method
Production lossesProduction losses
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
20/27
Thickness profiles for thermalThickness profiles for thermal
experimental conditionsexperimental conditions
4 experiments4 experiments
Polymer temperature and hopperPolymer temperature and hopper
temperature are variedtemperature are varied 2 experiments are conducted with polymer2 experiments are conducted with polymer
temperature greater than hoppertemperature greater than hopper
temperaturetemperature Other two with polymer temperature lessOther two with polymer temperature less
than hopper temperaturethan hopper temperature
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
21/27
Thickness profilesThickness profiles
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
22/27
Tagucchi methodTagucchi method
major points of his quality philosophymajor points of his quality philosophy
In a competitive market environment,In a competitive market environment,
continual quality improvements and costcontinual quality improvements and costreductions are necessary for businessreductions are necessary for business
survivalsurvival
An important measurement of the quality ofAn important measurement of the quality ofa manufactured product is the total lossa manufactured product is the total loss
generated by that product to the society.generated by that product to the society.
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
23/27
Change the preChange the pre--production experimentalproduction experimental
procedure from varying one factor at a timeprocedure from varying one factor at a time
to varying many factors simultaneouslyto varying many factors simultaneously(SDE) , so that quality can be built into the(SDE) , so that quality can be built into the
product and the process.product and the process.
definition of quality from "achievingdefinition of quality from "achieving
conformance to specifications" to "achievingconformance to specifications" to "achieving
the target and minimizing the variabilitythe target and minimizing the variability
objectivesobjectives
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
24/27
Highlights, Accomplishments, andHighlights, Accomplishments, and
RecommendationsRecommendations
Capacity gained through the AU processCapacity gained through the AU process
AU+Process optimization frameworkAU+Process optimization framework
Development of the predictive modelDevelopment of the predictive model--establishes the relationship betweenestablishes the relationship between
processprocess--product relationshipproduct relationship
Additional work and activitiesAdditional work and activities Applying the manufacturing optimizationApplying the manufacturing optimization
strategy to other manufacturing processesstrategy to other manufacturing processes
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
25/27
MachineMachine Curr. yieldCurr. yield YieldYield
improvemimprovem
entent
CapacityCapacity
gaingain
CC 6868 8585 1717
DD 8080 8585 55
FF 6969 8585 1616
GG 8585
HH 7272 8585 1313
II 7979 8585 66
MM 8181 8585 44
OO8585
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
26/27
AU as a driver for improvementAU as a driver for improvement
activitiesactivities
8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation
27/27
CONCLUSIONCONCLUSION
This strategy can be used for otherThis strategy can be used for other
manufacturing operations too.manufacturing operations too.