HEMANT PATIL

MCM04

PRODUCTIVITY IMPROVEMENT TECHNIQUES

CONTENTS

PRODUCTIVITY

PRODUCTIVITY IMPROVEMENT

PRODUCTIVITY IMPROVEMENT TECHNIQUES

AUTOMATION

CASE STUDIES

PRODUCTIVITY

Output

SYSTEM

transformationsInputs

productivity

O

I

Customers

Goods

and

services

Land

people

capital

facilities

equipment

tools

energy

materials

information

PRODUCTIVITY IMPROVEMENT

• Increase output while input remains same

• Decrease input while output remains same

• Increase input resulting in a very large increase in

output

• Decrease input by a very large amount with a

resultant small reduction in output

PRODUCTIVITY IMPROVEMENT TECHNIQUES

• CAD/CAM

• CIM

• ROBOTICS

• SHIGEO SHINGO PRINCIPLES

• GROUP TECHNOLOGY

• JOB ROTATION

• TQC

CAD/CAMCADA software system that uses computer graphics to assist in

the:

• Creation

• Modification

• analysis of a design

CAMUse of computer system to plan, manage and control the

operation of a manufacturing plant through either direct or indirect computer interface.

COMPUTER INTEGRATED MANUFACTURING

• CIM is the architecture for integrating the engineering, marketing, and manufacturing functions through information technologies.

ROBOTICS

• “A robot is a reprogrammable, multifunctional manipulator designed to move material, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks.”

SHIGEO SHINGO PRINCIPLES

Dr. Shingo Shigeo’s teachings can be classified into the three concepts listed as follows.

• Just In Time (JIT).

• Single Minute Exchange of Dies (SMED).

• Zero Quality Control.

JIT

“JUST IN TIME”

• A philosophy of manufacturing based on planned elimination of all waste and continuous improvement of productivity.

SMED

SINGLE MINUTE EXCHANGE OF DIE

• It is one of the world class manufacturing techniques. By implementing the Set up Reduction, we can reduce waste time during machining and hence we can improve our production rate on that machine.

Zero Quality Control

Dr. Shigeo Shingo’s Zero Quality Control (ZQC) techniques make use of the following engineering principles:

100 percent inspections done at the source instead of sampling inspections

Immediate feedback from successive quality checks and self checks

GROUP TECHNOLOGY

• Group technology is a manufacturing

philosophy in which similar parts are identified

and grouped together to take advantage of their

similarities in manufacturing and design.

JOB ROTATION

Job rotation is a management technique that

assigns trainees to various jobs and departments

over a period.

Job Rotation is frequently used with new trainees

who are just entering the workforce. Trainees

gain perspective on various areas of the

organization. This provides an opportunity to

work with higher management and different

departments.

TOTAL QUALITY CONTROL

Total-Made up of whole.

Quality-Degree of excellence of a Product or service.

Management-Act,art,manner of handling controlling directing etc.

TQM is an art of Managing the whole to achieve excellence.

AUTOMATION

MANUAL OPERATED MACHINES SEMI-AUTOMATED MACHINES

AUTOMATIC MACHINES

CASE STUDY

PRODUCTIVITY WITH CONVENTIONAL MACHINING AND ADVANCED TECHNIQUES

CHALLENGE

GEX’s leaders determined they would need to improve profits 15 percent to 20 percent without adding resources in order to maintain their leading position.

SEWING LINEBEFORE AUTOMATION AFTER AUTOMATION

CUTTING LINE

BEFORE AUTOMATION AFTER AUTOMATION

RESULTS

Modifying production line for productivity improvement A Case Study of Vision Lens Factory

OPERATION PROCESS CHART

PROCESS LAYOUT OF ASSEMBLY AND FILLING STATION OF CURRENT LINE

PROCESS LAYOUT OF ASSEMBLY AND FILLING STATION OF IMPROVED LINE

RESULTS

THANK YOU….