SVKM's Narsee Monjee
Mukesh Patel School of Technology
Management & Engineering, NMIMS
A REPORT
ON
IMPROVEMENT IN OEE BY DECREASEING
CHANGEOVER TIME
BY
SHUBHAM RAJESH TYAGI
COOPER STANDARD AUTOMOTIVE
A REPORT
ON
IMPROVEMENT IN OEE BY DECREASEING
CHANGEOVER TIME
By
SHUBHAM RAJESH TYAGI
A report submitted in partial fulfillment of the
requirements of 5 years Integrated MBA (Tech)
Programming of Mukesh Patel School of
Technology Management & Engineering,
NMIMS
ABSTRACT
The exploration for improving productivity in the current global competitive
environment has created a need for rigorously defined performance
measurement system in a manufacturing process. OEE, a vital KPI of TPM is
used to evaluate performance and productivity of the machine. OEE is one of
the performance evaluation methods that are most common and popular in
the production industries. This project tries to improve the OEE index on
extrusion machine in organization and identifies the main loss elements in the
changeover process. OEE data on machine performance is an initial key point
to understand the equipment losses and establish improvement to eliminate
them. The results are compared with world class level.
Abbreviations: - O.E.E (Overall Equipment Effectiveness)
T.P.M (Total Production maintenance)
S.M.E.D (Single Minute Exchange of Die)
EXTRUSION (machine)
INTRODUCTION
Auto weather-strips (weather-stripping) are a crucial part of any vehicle which
effectively seal the inside of the vehicle and prevent various outside elements
like water, air, dust and noise from entering the vehicle cabin. Now, the mostly
used material for manufacturing weather-strips is EPDM rubber which has
superior resistance to outdoor weather, water, ozone, sunlight, etc. TPE/TPV
and PVC are also used for some parts. With state-of-the-art of manufacturing
and testing equipment, Cooper Standard automotives has grown to be a
leading supplier of vehicle sealing systems and can design, develop and
manufacture nearly all the rubber and plastic weather-strips and trim seals
that contribute to the performance and comfort in a car.
Sealing Capabilities
- Provides extensive vehicle body, door and glass seals extruded from
EPDM (ethylene propylene di-ene monomer M-Class rubber), TPE
(thermoplastic elastomer) and PVC (polyvinyl chloride) that can be
reinforced with steel, aluminum and / or wire carriers to provide the
broadest product line-up.
- Leverage of extensive material knowledge to provide the correct
dynamic seal solution to meet all of the customer performance
requirements.
- Utilizes TPV (thermoplastic vulcanizate) and PP
(polypropylene)
seals to reduce weight on products, such as glass runs and waste
belts.
- Has the ability, through its patented process, to provide a one-piece
co-extruded assembly with glass run lips integrated below the belt
channel to provide weight savings.
- Fully integrated day light opening trim and seal systems to
improve the vehicle aesthetics and transitions among mating
components.
- Provides customers with the ability to improve vehicle sealing
aesthetics with uniform appearance.
- Reduces complexity at assembly plants and provides ease of
installation and enhanced reliability by offering modular solutions that
are co-extruded with EPDM, TPE and PVC.
- Value added glass run systems available to meet all of the
customers differentiation requirements and needs.
PRODUCTS
Rubber Products Line Card:
Primary Door Seals (mounted on door)
Secondary Door Seals(mounted on vehicle body)
Window Glass Run Channels
Inner and Outer Belt Weather-strips
Windshield Weather-strips, Seals & Gaskets
Hood/Bonnet Rubber Seals & Weather-strips
Trunk/Tailgate Bulb Trims & Seals
Sunroof Weather-strips & Seals
Other rubber seals: roof line seals, cowl seals, air conditioning EPDM tube insulation, quarter window seals
Description of the product:
Primary door seal (Door mounted):
The rubber seal is attached to vehicle door with self-adhesive tape or plastic
retaining clips and acts as the first sealing barrier between vehicle door and
body. The primary door seal is used together with secondary door seal to
achieve better performance.
Material:
EPDM Sponge Rubber
EPDM Solid Rubber + EPDM Sponge Rubber
Secondary door seal (body mounted):
The rubber seal (trim seal) fits into vehicle body panel and plays a major role
in isolating the vehicle cabin from outside water, air, dust and noise. The door
seal also buffers impacts from the opening and closing of door and ensures
easy closing and better sealing effect. It is often coated with colored EPDM
rubber which has the same pattern with vehicle interior to provide elegant
appearance.
Material:
EPDM Solid Rubber + EPDM Sponge Rubber + Metal Carrier
EPDM Solid + EPDM Sponge Rubber + Metal Carrier + Colored EPDM Coat
Window glass run channel:
Glass run channel is mounted to insides of the automotive door window frame
and enable movable window glass to slide freely, and also stabilizes the glass
during glass movement and door closing. The rubber channel is covered by
flock or coated with abrasion resistance polyurethane(PU) coating to minimize
friction during movement of the glass.
There are four types of glass run channels
Flocked Glass Run Channel (EPDM Solid Rubber + Flock)
Coated Glass Run Channel (EPDM Solid Rubber + PU Coating)
Hybrid Glass Run Channel (EPDM Solid Rubber + TPE Slip-coating)
TPE-V (TPV) Extruded Glass Run Channel (TPV + Co-extrued on slipcoating)
Inner and outer beltline weatherstrip:
Beltline weatherstrips are mounted along the beltline of vehicle door
preventing outside weather elements from entering vehicle compartment, and
also stabilize the window glass during its movement. Beltline weatherstrips
have flocked surfaces which help reduce friction and noise.
Material:
PVC+Metal Insert+Flock
Front and Rear Windshield Weatherstrip:
A windshield weatherstrip surrounds the windshield glass and keep it in place.
Windshield weatherstrips prevent air, water, dust and noise from entering
insides of vehicle cabin.
Material:
1 EPDM Solid Rubber
Hood Weatherstrip:
Hood seals act as sealing barrier between hood and the front portion of
vehicle body.
Material:
1 EPDM Sponge Rubber
2 EPDM Solid Rubber + EPDM Sponge Rubber
Trunk Weatherstrip/Tailgate Weatherstrip:
The rubber seal(top bulb trim seal) fits into body panel around the trunk and
prevents air, water and debris from entering the trunk compartment.
Material:
1 EPDM Solid Rubber + EPDM Sponge Rubber + Metal Carrier
PROJECT DESCRIPTION
Detailed study of Extrusion line and study of OEE (Overall
equipment effectiveness) to reduce changeover time of the
operation.
OEE is a highly effective Business Performance Management
Tool, which critically evaluates how effectively a manufacturing
operation is utilized? OEE can be used on single and multiple
production lines and from one to a number of plants in a groupwide structure. It is suitable for all types of manufacturing
processes including discrete, continuous or bulk. Put simply
OEE measures the gap between the actual performance and the
potential performance of a manufacturing unit.
Availability
Availability takes into account all events that stop planned production long
enough where it makes sense to track a reason for being down (typically
several minutes).
Availability is calculated as the ratio of Run Time to Planned Production Time:
Availability = Run Time / Planned Production Time
Run Time is simply Planned Production Time less Stop Time, where Stop
Time is defined as all time where the manufacturing process was intended to
be running but was not due to Unplanned Stops (e.g., Breakdowns) or
Planned Stops (e.g., Changeovers).
Run Time = Planned Production Time Stop Time
Performance
Performance takes into account anything that causes the manufacturing
process to run at less than the maximum possible speed when it is running
(including both Slow Cycles and Small Stops).
Performance is the ratio of Net Run Time to Run Time. It is calculated as:
Performance = (Ideal Cycle Time Total Count) / Run Time
Ideal Cycle Time is the fastest cycle time that your process can achieve in
optimal circumstances. Therefore, when it is multiplied by Total Count the
result is Net Run Time (the fastest possible time to manufacture the parts).
Since rate is the reciprocal of time, Performance can also be calculated as:
Performance = (Total Count / Run Time) / Ideal Run Rate
Performance should never be greater than 100%. If it is, that usually indicates
that Ideal Cycle Time is set incorrectly (it is too high).
Quality
Quality takes into account manufactured parts that do not meet quality
standards, including parts that need rework. Remember, OEE Quality is
similar to First Pass Yield, in that it defines Good Parts as parts that
successfully pass through the manufacturing process the first time without
needing any rework.
Quality is calculated as:
Quality = Good Count / Total Count
This is the same as taking the ratio of Fully Productive Time (only Good
Parts manufactured as fast as possible with no Stop Time) to Net
Run Time (all parts manufactured as fast as possible with no stop
time).
OEE
OEE takes into account all losses, resulting in a measure of truly productive
manufacturing time. It is calculated as:
OEE = Availability Performance Quality.
If the equations for Availability, Performance, and Quality are substituted
in the above and reduced to their simplest terms the result is:
OEE = (Good Count Ideal Cycle Time) / Planned Production Time
This is the simplest OEE calculation described earlier. And, as
described earlier, multiplying Good Count by Ideal Cycle Time
results in Fully Productive Time (manufacturing only Good Parts, as
fast as possible, with no Stop Time).
TASK ALLOTTED
Changeover is the process of converting a line or machine from
running one product to another. Changeover times can last from a few
minutes to as much as several weeks in the case of automobile
manufacturers retooling for new models. The terms set-up and
changeover are sometimes used interchangeably however this usage is
incorrect. Set-up is only one component of changeover.
Clean-up
Cus product, materials and components from the line. It may range from
minor, if only the label of a package is being changed (for example from an
English to a Spanish label) to major, requiring complete disassembly of the
equipment, cleaning and sterilizing of the line components in the case of an
injectable pharmaceutical product.
Set-up
Set-up is the process of actually converting the equipment. This may be
achieved by adjusting the equipment to correspond to the next product or by
changing non-adjustable "change parts" to accommodate the product.
Typically, it will be a combination of both.
Start-up
Start-up is the time spent fine tuning the equipment after it has been
restarted. It is characterized by frequent stoppages, jams, quality rejects
and other problems. It is generally caused by variability in the clean-up
and set-up or by variability in the product or its components.
SIX BIG LOSSES IN MANUFACTUING PROCESS
SIX BIG LOSS
CATEGORY
OEE LOSS
CATEGORY
EVENT EXAMPLES
W.R.T
EXTRUSION
PROCESS
Break Downs
Down Time Loss
Setup and Adjustments
Down Time Loss
Small Stops
Speed Loss
Reduced Speed
Speed Loss
Start-up Rejects
Quality Loss
Production Rejects
Quality Loss
Die changing
Equipment Failure
Unplanned
Maintenance
Setup/changeover
Extruder Shortages
Unskilled operator
Warm-up Time
Cleaning
Sieve Blocked
Temperature settings
Equipment Wear
Under Design
capacity
Scrap
Reworks
Printing Problems
Length Variations
Scrap
Rework
Texture Change
TIME STUDY:
A work measurement technique for recording the time and rate of worker
for the elements specified to carry out a job under different conditions or
under specified conditions for analysis of data so as to determine the time
necessary to carry out a job at a defined level of performance.
OBJECTIVE OF TIME STUDY
Comparing alternative methods
Planning and controlling
Delivery date of product from a complete manufacturing system
Cost reduction and cost control
Elimination of scrap
STEPS INVOLVED IN MAKING OF TIME STUDY:
1) SELECT: Selection of manufacturing line.
2) OBTAIN AND RECORD: Details and study about the methods,
operator, job and working conditions
3) DEFINE: Defining the manufacturing line and breaking the line into
smaller elements for detailed study
4) MEASURE: Measure the time duration of each element and then give
performance rating
5) EXTEND: Observe time into normal time
6) DETERMINE: Determine different allowances given to a worker
7) COMPUTE: Compute standard time for the manufacturing line and
other standard values.
Reduction in changeover time by analyzing the changeover activities
and detecting sources of errors causing increase in the changeover
which ultimately increases the machine uptime.
Below is shown a real time example of changeover activities and
time spend in doing them.
(READINGS ARE TAKEN IN COOPER STANDARD AUTOMOTIVES
PVT.LTD)
Time study done on Extrusion Line No:6 (using stop watch)
Previous Profile : Nissan Glass run BB
Next Profile: Nissan Glass run CC
Man Power :5
Change over Start Time: 16:00
Last Ok product of previous profile: 16:07
First Ok Product OF next profile: 16:40
Observations:
Lack of supervision .
Lack of man power
Untrained worker did a mistake during the initial setup due to which the
last part of setup had to done again which increased its time.
Small process like printing, cutting and lip opening (a essential non
value adding activity) setups could be done before or during the EPDM
profile is being taken from start to end.
Recommendations
Presence of a supervising figure is essential.
A group of 2-3 workers should prepare dies and other changeover parts
beforehand for all changeovers during their shift.
Proper training should be given to new workers.
CATEGORIES OF TASKS
EXTERNAL: Tasks which can be done before initiation of changeover
i.e. these task do not require the whole machine/line stoppage and can
be prepared beforehand.
Eg: Die issuing from Tool room, Preformer tool change etc.
INTERNAL: Task which cannot be done beforehand and are only done
when the machine/line stops for changeover.
Eg: Drilling machine guide and drill change, Die putting and nut
tightening etc.
METHODS INVOLVED IN REDUCING CHANGEOVER:
SMED (Single Minute Exchange of Die)
Single Minute Exchange of Die (SMED), or Fast Changeover, is as the
name suggests the method by which equipment can be changed from one
product to the next in the most effective way, and in the shortest possible time.
Single Minute Exchange of Die is an objective whereby all changeovers
are completed in a single number of minutes (less than 10). S.M.E.D. is
an integral part of T.P.M. (Total Productive Maintenance)
KEY STEPS FOR DECREASING CHANGEOVER TIME
Identifying and selecting a process improvement team consisting of best
setup/machine operators that are able to identify and separate internal
and external steps
Starting with current state - selecting and focusing on one
machine
Walk-through the entire setup process, in detail, and recording
the steps in written or video format
Identifying detailed internal setup steps as these require the
machine to stop
Example: Removing a die from a Extruder machine.
Identifying detailed external steps - steps that may be performed as
the machine is running
Example: Obtaining the die required for the next job while the current
job is in progress
Separating the work while the machine is stopped in order to categorize
each activity as either internal or external
Converting internal steps to external steps
-
What external steps of the setup process are being treated as
internal steps? Example: Planning every day and communicating
which machines will require setups, and calculating approximately
when they will take place
Preparing dies, tooling, and materials outside of the department
(tool room) while the current job is still running.
Reducing remaining Internal Work
Working with machine operators and setup people for better
understanding of what their challenges are.
remove these barriers so they focus more on fast changeovers
rather than performing non-valued added tasks
Creating improved setup/changeover process
Capturing and analyzing accurate setup data, then focuing on the
steps wasting the most time
Asking operators for their thoughts
Training all operators/setup people in the new process
Clearly labeling, organizing, storing, and maintaining all tooling to
minimize surprises
Using dowels or go-no go fastening systems to eliminate
adjustments in the first place, ensuring tooling is cleaned and
maintained as it is returned to its stocking location after previous
use
REFERENCES:
Cooper Standard automotives product catalogue
Cooper Standard automotives HR manual.
Wikipedia
Oee.com
Activity data sheet. (self prepared)
