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6.4.2 Weekly
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OEE FOR THE MONTH OF APRIL Item Shift Length Short Breaks Meal Break Down Time Ideal Run Rate Total Pieces Reject Pieces Table 5: Data for the month of April Data 8hrx2shiftsx24days = 23040min. 2 @ 15 min. = 30 min. 1 @ 30 min. = 30 min. 2256 minutes 1 pieces per minute 14348 pieces 893 pieces
Planned Production Time= [Shift Length - Breaks] = [23040 - 2880]= 20160 minutes Operating Time= [Planned Production Time - Down Time] = [20160 - 2256] = 17904minutes Good Pieces= [Total Pieces - Reject Pieces] = [14348 - 893] = 13455 pieces
Availability
Operating Time / Planned Production Time 17904 minutes /20160minutes 0.89 (89%)
Performance = =
(Total Pieces / Operating Time) / Ideal Run Rate (14348 pieces /17904 minutes) / 1 pieces per minute 0.82(82%)
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Quality = =
Availability
Operating Time / Planned Production Time 17712 minutes /20160minutes 0.87 (87%)
OEE = =
HENCE WE CAN SEE THERE IS A RISE IN THE OEE AFTER IMPLEMENTING TPM TECHNIQUES.
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Revenue Quoted
= 13850 x 80
= 1108000 Rupees
Actual revenue
= 12890 x 80
=1031200 Rupees
= 960 x 80
= 76800 Rupees
Loss
DOWNTIME Ideal run rate Products that could have been produced during downtime Revenue that could have been generated during downtime
Due
To
Downtime
= 3960 minutes = 1 piece per minute
=316800 Rupees
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COST ANALYSIS FOR THE MONTH OF APRIL: Revenue Quoted = Total product produced x price per piece Actual Revenue = Total no of Quality product x price per piece Loss due to rejected = Scraps x price per piece = 893 x 80 = 71440 Rupees =13455 x 80 =1076400 Rupees = 14348 x 80 = 1147840 Rupees
Loss
DOWNTIME Ideal run rate products that could have been produced during downtime revenue that could have been generated during downtime
Due
To
Downtime
= 2256 minutes = 1 piece per minute
Pieces x rupees
= 2256 X 80
=180480 Rupees
A significant reduction in down time can be observed from the month of February to April.
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Conclusion
The press brake machine which did not have proper maintenance and was creating bottleneck in the production, now has higher overall equipment effectiveness. Also noticeable is the reduction of defects in the samples.
TPM has also created awareness among the operators, a sense of responsibility and also
provided a safe working environment for them. TPM has increased the availability of the machine due to good maintenance, has increased revenue for the company and hence acts as a cost saving tool.
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References
1. Implementation of TPM- Steve Borris 2. www.plant-tpm.com 3. www.tpmclubofindia.com
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