Most essential tool for supervisor

by

Suresh.T

ssuresh.t24@gmail.com

EPP this tool specially made for supervisor and also  manageable. The supervisor is the first management staff who has direct contact with workers most probably an improvement of an organization starts base from supervisor. In Indian industries, most of the organizations scare to take workers as company employee they prefer contract people due to some of the reasons like union, productivity etc.,

I hope that this tool will help to find solutions. EPP is nothing but ranking method. In

detail manner to evaluate workers.

EPP is evaluating workers in a pyramid form in the following categories.

SafetyQuality & ProductivityPunctuality & disciplineAttendance5s & instruments handlingMulti skilled & flexibilityKeep improvements (kaizen) or suggestions

The first most important things in any industries is safety. The first thing the supervisor should not compromise for safety at any time.

Tool: For, thus we can use simple tools. There is a board in

working place for “safety disobedience”. Who is not following safety rules like grinding without using goggles, handling component without gloves etc., should write their name on that board. This rule is common for all. The punishment like fine, loss of pay etc.,

There is a leader for safety for every shift. He is responsible for that board however everyone can list out the name who are all disobeying the safety.

According to name in the board, can construct pyramid of the employee.

We consider quality and productivity in same factor to find this efficiency we can use tool OME (Overall Machine vise efficiency). See, the sample of calculating OME data.

Machine No Operator name OF No Order no Item no Part Description Material Operation Prdn.Qty Rw.Qty Avl.Time Utilized time

Loss time in Min. Down Time in Min. Rework Time in Min. Machine shop Efficiency Overall operator's efficiency

Setting Tool/ Fixt. Others Break down

No operator No load Mcshop Assly Subcon Foundry Welding Std.Cycle Time Std. Prodn time % Accepted Qty Utilized Quailty OOE in %

L-1 S.DHAMOTHARAN

795 7 2''300 SK BONNET C5 THD 2

440 500

30 0

57% 8.00 1.14 0.80 90.91

732 4 4''600 GK YOKE CF8M THD 2 20 60 120

695 2 2''300 GK BONNET CF8M PRE M/C 2 20 20 40

#N/A #N/A #N/A #N/A 1 OPP 2 45 90

#N/A #N/A L-8 TOLL POST ROD&PLATE M.S M/C 2 20 160 0

OME (Overall Machine vise efficiency) is the format use to find the following data for individual machines.

• Utilization efficiency• Production efficiency• Operator’s efficiency• Individual losses time & percentage

Available time: Available time nothing but standard time

i.e., total time minus planned loss.

Ex: Total shift hrs = 8 hrs = 480 min Planned loss = Lunch & tea break = 45 min Available time = Total min – planned loss = 480-45 = 435 minNote : Available time is always standard.

To find utilization efficiency , minus no load, no operator & breakdown losses from available time. After that add all the losses with standard production time. Then, ratio of utilized time to available time.

Ex: Available time = 435 minIf, Break down = 60 min Utilized time = 375 min Utilized efficiency = (375/435) * 100 = 86%Note: The utilization efficiency based on supervisor

review which does not simply write by workers. At the same time the losses also have standard time. Ex: Setting time for certain unit is 30 min, machine cleaning 10 min etc., Further, we can see detail about losses.

To find production efficiency, multiply produced units with standard cycle time. Then the ratio of production time to available time.

Ex: Produced units = 10 Cycle time/ unit = 30 min Production time = 10*30 =300 min Production efficiency = (300/435)*100 = 69%

To find operator efficiency want to multiply utilized efficiency with quality efficiency. The quality efficiency is ratio of accepted units to total units.

Ex: Utilized efficiency = 86%= .86 If one unit is rejected from produced unit 10. Accepted units = 10-1 =9 Quality efficiency =9/10 = .9 Operators efficiency = .9*.86 = 77.4%

According to losses in our working atmosphere we can choose our category. Rarely happening losses choose as other losses.

Ex: Setting, tool issue, Fixture issue

etc., The operator should clearly fill the

losses in job card. It will be review by supervisors.

MACHINE SHOP JOB CARD

operator name: Date:

Shift: Machine:

S no Part Description Operation Order no.& Item no.

Prod Qty

RW Qty

Rej. Qty PR CT RW SE MB TI NL NO OT Remarks

Operations: 1st, 2nd, 3rd, 4th, Serr (Serration), BM (Blue matching), RW(Rework), SF(Semi finish)

SFF (Semi finish finished), Thd. (Therading)

Operator sign Shift incharge sign

PR- Production time, CT- Cycle time, RW- Rework time, SE- Setting timeMB- Breakdown/ Power cut, TI- Tool/fixture issue, NL- No load, No- No operator, OT- Others

Start time

End time

Review byEnd time

Total time

Review by

MACHINE SHOP JOB CARD

S.no Time Short

cutsStart time

Total timeS.noTime short

cuts

The above job card should fill by operators. It will be review by supervisors. When entering the data in OME. We will get clear view of all the losses & efficiency data.

Job card is most important tool for supervisor. He should review and sign periodically.

By help, of this percentage we can design pyramid of the operators.

This is another most important thing to workers. The punctuality and discipline it depends upon supervisor attitude and behavior. He is the only person responsible for this and he should role model to all workers.

Punctuality: The punctuality is not In time or Out time note

by security. The operator should enter before the shift starts and get a clear idea of current running condition of machine in detailed manner. At the same time, he is also give details in clearly to forthcoming operator. Always, there should be a time keeping.

Punctuality it should be monitored visually by supervisors and also record of accident or mistake due to communication or misunderstanding mistake.

According to communication error, we can construct a pyramid of workers.

Discipline: Discipline it is also tool monitor visually by

supervisors and also record of accident or mistakes due to careless because most of the careless mistakes happening due to the misbehavior of operators.

Ex: During operation in machine, unnecessarily talking with another operator.

Unnecessarily roaming here and there.

RRA is nothing but rework, rejection & accident which happening in machine, tool and component. It is a tool which is used for analysis for every operators’s mistake. For, frequently happening mistake make an open suggestion among all operators to find the correct solution in the weekly meeting.

Ex:

The important thing is there is no separate bathroom for workers and staff. There should be common for both of them. During, working hours most of the workers spending needlessly in bathroom like talking with their colleague, sleeping, sitting for hours. So, to avoid this there should be a common bathroom for all. So they have scare at any time the higher officer will come.

If, the company allow smoking, the smoking room it should be also common for workers and staff.

Whatever the thing distracting production it should not allow to the industries.

Ex: Mobile usage during working hours.

It is also an important thing to monitor. Every company there is a CL and EL leaves. Most of the workers taking leave more than that it affects most of our productions.

Tool: It can simply monitor by normal attendance. At

the same time except emergency purpose, Who are all taking not informed leave, last time leave etc., It should reduce in percentage.

It can also monitor by using OME data, by considering the zero percentage when taking an average. According to this we can construct pyramid.

5s are the basic to all workers. It should follow strictly at every moment. Most of the workers followed 5s at the last moment or at the time of auditing, it should be avoided.

Another one is instrument handling and maintaining. It should teach carefully to the workers, how to handle as well as a measure. Due to this most of the quality problem will avoid.

Tool: For this , we can use MSA as well as 5s auditing

process other than that whenever get a time watch the operator whether they following correctly. According, to this we can construct pyramid.

In one-off or small batch production company. It is the important thing need to all workers.

Tool: There is no specific tool for this. It mostly

depends upon supervisor work allotment at the same time training which also given to workers according to their job order.

Pyramid is construct , according to monitor by supervisors.

Another important thing to monitor, because according to their experience, skill, operator does not increase their production. So there should be a cycle time data according to this. There should be made any cycle time reduction by Kaizen, SMED, skill etc.

Tool: If any cycle time reduction made note that new

cycle time make a standard cycle time. According to that cycle time training should give to all the workers.

According to cycle time reduction or improvement made, we can construct pyramid.

EPP it is a tool want to update weekly or monthly by supervisors. It should display in notice board.

Who are all getting more pyramid marks they should reward and appreciate by management in monthly meeting.

Who are all getting low pyramid marks they should train in a weaker section.

Evaluation depends upon score, stars etc., Now we can see sample pyramid in a score form.