A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation

8/8/2019 A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation

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AA systemicsystemic Strategy forStrategy foroptimizing manufacturingoptimizing manufacturing

operationsoperations

Presented ByPresented By

HANUMANTHARAJU .LHANUMANTHARAJU .L

1BM05IM0151BM05IM015

dept. of IEM,dept. of IEM,

BMSCEBMSCE


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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


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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


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Polymer sheet formationPolymer sheet formation


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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


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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


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Productivity parametersProductivity parameters


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AU definitionsAU definitions


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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%


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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


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Flow diagram of casting processFlow diagram of casting process


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Parallel activities of optimizationParallel activities of optimization

frameworkframework


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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


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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


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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


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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


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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.


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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


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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


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Thickness profilesThickness profiles


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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.


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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


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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


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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


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AU as a driver for improvementAU as a driver for improvement

activitiesactivities


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CONCLUSIONCONCLUSION

This strategy can be used for otherThis strategy can be used for other

manufacturing operations too.manufacturing operations too.

A Systemic Strategy for Optimizing Manufacturing Operations Power Point Presentation

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