SYSTEMATIZATION, IMPLEMENTATION AND ANALYZE OF OVERALL THROUGHPUT EFFECTIVENESS CALCULATION IN FINISHING PROCESS OF WEAVING INDUSTRY
Abstract
Özet
Sürekli iyileşmenin
sürdürülebilirliği için, üretim alanından mümkün olduğunca fazla veri almanın önemi
tartışılamaz. Ancak, bu verileri, yalın üretim
sisteminde anahtar performans göstergelerine dönüştürmek çok daha önemlidir.
Bu makale, gerçek üretim ortamında, dokuma
endüstrisinin finisyon sürecine odaklanmıştır. Çalışmada, öncelikle RFID ve PLC
otomasyon yapısı ile barkod bazlı izlenebilirlik sağlanmıştır. Sonraki aşamada,
her bir süreç için genel ekipman etkinliği (OEE)’nin hesaplanması sağlanmış ve özgün
bir gösterge olarak genel çıktı etkinliği (OTE)’ne dönüştürme yöntemi
önerilmiştir. Makalenin son aşamasında, genel
çıktı etkinliği değerinin otomatik olarak alınmasından sonra, üretim ortamı
parametreleri ile gösterge (OTE) arasındaki ilişkinin ortaya çıkarılması
hedeflenmiştir. OTE sonuçlarını etkileyen en
önemli üretim ortamı parametrelerini bulmak için, Revize Melez Genetik
Algoritma önerilmiştir. Geliştirilen algoritmanın sonucunu doğrulamak için ise
Çoklu Doğrusal Regresyon kullanılmıştır. (Bu
çalışma, Güncel Yazılım Ar-Ge Merkezi ve Türkiye Bilimsel ve Teknik Araştırma
Kurumu (TÜBİTAK-TEYDEB- 7151608) tarafından desteklenmiştir.)
Anahtar
Kelimeler: Genel Çıktı Etkinliği, Genel Ekipman Etkinliği, Finisyon Süreci, Dokuma
Endüstrisi
Abstract
For the sustainability
of continuous improvement, the importance of getting as much data as possible
from production field is indisputable. But, converting these data to key
performance indicators in lean production system is much more important. This paper
focused on finishing process of weaving industry, in real production plant. In
the study, firstly, barcode based traceability was provided by RFID and PLC
automation structure. In the next step, the calculation of the general
equipment efficiency (OEE) for each process was provided and then a method of
converting these OEE values to the unique indicator as general output efficiency
(OTE) was proposed. In the last phase of the paper, after getting OTE value
automatically, it was aimed to reveal the relationship between production
environment parameters and indicator of OTE. Revised Hybrid Genetic Algorithm was
proposed to find the most important production environment parameters that affect
OTE results. Multiple Linear Regression was utilized to verify the result of developed
algorithm. (This work supported by Güncel Yazılım R&D Center and The
Scientific and Technical Research Council of Turkey (TUBİTAK-TEYDEB- 7151608.))
Keywords: Overall
Throughput Effectiveness, Overall Equipment Effectiveness, Finishing Process, Weaving
Industry
References
- 1. Nakajima, S. (1988). Introduction to TPM: Total Productive Maintenance.(Translation). Productivity Press, Inc., 1988,, 129.
- 2. Jeong, K. Y., & Phillips, D. T. (2001). Operational efficiency and effectiveness measurement. International Journal of Operations & Production Management, 21(11), 1404-1416.
- 3. Huang, S. H., Dismukes, J. P., Shi, J., Su, Q., Wang, G., Razzak, M. A., & Robinson, D. E. (2002). Manufacturing system modeling for productivity improvement. Journal of Manufacturing Systems, 21(4), 249-259.
- 4. Nahar, K., Islam, M. M., Rahman, M. M., & Hossain, M. M. (2012, December). Evaluation of OEE for implementing Total Productive Maintenance (TPM) in sewing machine of a knit factory. In Proc. the Global Engineering, Science and Technology Conference (pp. 28-29).
- 5. Williamson, R. M. (2006). Using Overall Equipment Effectiveness: the Metric and the Measures, Strategic Work Systems. Inc., Columbus NC, 28722, 1-6.
- 6. Binti Aminuddin, N. A., Garza-Reyes, J. A., Kumar, V., Antony, J., & Rocha-Lona, L. (2016). An analysis of managerial factors affecting the implementation and use of overall equipment effectiveness. International Journal of Production Research, 54(15), 4430-4447.
- 7. Ahmed, M., & Ahmad, N. (2011). An application of Pareto analysis and cause-and-effect diagram (CED) for minimizing rejection of raw materials in lamp production process. Management Science and Engineering, 5(3), 87-95.
- 8. Green, C., & Taylor, D. (2016). Consolidating a Distributed Compound Management Capability into a Single Installation: The Application of Overall Equipment Effectiveness to Determine Capacity Utilization. Journal of laboratory automation, 21(6), 811-816.
- 9. Tsarouhas, P. H. (2013). Equipment performance evaluation in a production plant of traditional Italian cheese. International Journal of Production Research, 51(19), 5897-5907.
- 10. Vijayakumar, S. R., & Gajendran, S. (2014). Improvement of overall equipment effectiveness (OEE) in injection moulding process industry. IOSR J Mech Civil Eng, 2(10), 47-60.
- 11. Nachiappan, R. M., & Anantharaman, N. (2006). Evaluation of overall line effectiveness (OLE) in a continuous product line manufacturing system. Journal of Manufacturing Technology Management, 17(7), 987-1008.
- 12. TPM Chairman (2004) TPM activity pre audit report, Internal circulation copy, Sundaram Industries Limited, Madurai.
- 13. Braglia, M., Frosolini, M., & Zammori, F. (2008). Overall equipment effectiveness of a manufacturing line (OEEML) An integrated approach to assess systems performance. Journal of Manufacturing Technology Management, 20(1), 8-29.
- 14. Oechsner, R., Pfeffer, M., Pfitzner, L., Binder, H., Müller, E., & Vonderstrass, T. (2002). From overall equipment efficiency (OEE) to overall Fab effectiveness (OFE). Materials Science in Semiconductor Processing, 5(4), 333-339.
- 15. Muthiah, K. M. N., & Huang, S. H. (2007). Overall throughput effectiveness (OTE) metric for factory-level performance monitoring and bottleneck detection. International Journal of Production Research, 45(20), 4753-4769.
- 16. Muchiri, P., & Pintelon, L. (2008). Performance measurement using overall equipment effectiveness (OEE): literature review and practical application discussion. International Journal of Production Research, 46(13), 3517-3535.
- 17. Ahire, C. P., & Relkar, A. S. (2012). Correlating failure mode effect analysis (FMEA) & overall equipment effectiveness (OEE). Procedia Engineering, 38, 3482-3486.
- 18. Andersson, C., & Bellgran, M. (2011, January). Combining Overall equipment Efficiency (OEE) and productivity measures as drivers for production improvements. In Proceedings of the 4th Swedish Production Symposium (SPS11) (pp. 3-5).
- 19. Gibbons, P. M., & Burgess, S. C. (2010). Introducing OEE as a measure of lean Six Sigma capability. International Journal of Lean Six Sigma, 1(2), 134-156.
- 20. Yılmaz Eroglu, D. (2017). Calculating Overall Effectiveness in Serial Subsystem with Multiple Product. Journal of Current Researches on Engineering, Science and Technology (JoCREST), 3(2).
- 21. Eroglu, D. Y., & Kilic, K. (2017). A novel Hybrid Genetic Local Search Algorithm for feature selection and weighting with an application in strategic decision making in innovation management. Information Sciences, 405, 18-32.
- 22. Hall, M., Frank, E., Holmes, G., Pfahringer, B., Reutemann, P., & Witten, I. H. (2009). The WEKA data mining software: an update. ACM SIGKDD explorations newsletter, 11(1), 10-18.
Abstract
References
- 1. Nakajima, S. (1988). Introduction to TPM: Total Productive Maintenance.(Translation). Productivity Press, Inc., 1988,, 129.
- 2. Jeong, K. Y., & Phillips, D. T. (2001). Operational efficiency and effectiveness measurement. International Journal of Operations & Production Management, 21(11), 1404-1416.
- 3. Huang, S. H., Dismukes, J. P., Shi, J., Su, Q., Wang, G., Razzak, M. A., & Robinson, D. E. (2002). Manufacturing system modeling for productivity improvement. Journal of Manufacturing Systems, 21(4), 249-259.
- 4. Nahar, K., Islam, M. M., Rahman, M. M., & Hossain, M. M. (2012, December). Evaluation of OEE for implementing Total Productive Maintenance (TPM) in sewing machine of a knit factory. In Proc. the Global Engineering, Science and Technology Conference (pp. 28-29).
- 5. Williamson, R. M. (2006). Using Overall Equipment Effectiveness: the Metric and the Measures, Strategic Work Systems. Inc., Columbus NC, 28722, 1-6.
- 6. Binti Aminuddin, N. A., Garza-Reyes, J. A., Kumar, V., Antony, J., & Rocha-Lona, L. (2016). An analysis of managerial factors affecting the implementation and use of overall equipment effectiveness. International Journal of Production Research, 54(15), 4430-4447.
- 7. Ahmed, M., & Ahmad, N. (2011). An application of Pareto analysis and cause-and-effect diagram (CED) for minimizing rejection of raw materials in lamp production process. Management Science and Engineering, 5(3), 87-95.
- 8. Green, C., & Taylor, D. (2016). Consolidating a Distributed Compound Management Capability into a Single Installation: The Application of Overall Equipment Effectiveness to Determine Capacity Utilization. Journal of laboratory automation, 21(6), 811-816.
- 9. Tsarouhas, P. H. (2013). Equipment performance evaluation in a production plant of traditional Italian cheese. International Journal of Production Research, 51(19), 5897-5907.
- 10. Vijayakumar, S. R., & Gajendran, S. (2014). Improvement of overall equipment effectiveness (OEE) in injection moulding process industry. IOSR J Mech Civil Eng, 2(10), 47-60.
- 11. Nachiappan, R. M., & Anantharaman, N. (2006). Evaluation of overall line effectiveness (OLE) in a continuous product line manufacturing system. Journal of Manufacturing Technology Management, 17(7), 987-1008.
- 12. TPM Chairman (2004) TPM activity pre audit report, Internal circulation copy, Sundaram Industries Limited, Madurai.
- 13. Braglia, M., Frosolini, M., & Zammori, F. (2008). Overall equipment effectiveness of a manufacturing line (OEEML) An integrated approach to assess systems performance. Journal of Manufacturing Technology Management, 20(1), 8-29.
- 14. Oechsner, R., Pfeffer, M., Pfitzner, L., Binder, H., Müller, E., & Vonderstrass, T. (2002). From overall equipment efficiency (OEE) to overall Fab effectiveness (OFE). Materials Science in Semiconductor Processing, 5(4), 333-339.
- 15. Muthiah, K. M. N., & Huang, S. H. (2007). Overall throughput effectiveness (OTE) metric for factory-level performance monitoring and bottleneck detection. International Journal of Production Research, 45(20), 4753-4769.
- 16. Muchiri, P., & Pintelon, L. (2008). Performance measurement using overall equipment effectiveness (OEE): literature review and practical application discussion. International Journal of Production Research, 46(13), 3517-3535.
- 17. Ahire, C. P., & Relkar, A. S. (2012). Correlating failure mode effect analysis (FMEA) & overall equipment effectiveness (OEE). Procedia Engineering, 38, 3482-3486.
- 18. Andersson, C., & Bellgran, M. (2011, January). Combining Overall equipment Efficiency (OEE) and productivity measures as drivers for production improvements. In Proceedings of the 4th Swedish Production Symposium (SPS11) (pp. 3-5).
- 19. Gibbons, P. M., & Burgess, S. C. (2010). Introducing OEE as a measure of lean Six Sigma capability. International Journal of Lean Six Sigma, 1(2), 134-156.
- 20. Yılmaz Eroglu, D. (2017). Calculating Overall Effectiveness in Serial Subsystem with Multiple Product. Journal of Current Researches on Engineering, Science and Technology (JoCREST), 3(2).
- 21. Eroglu, D. Y., & Kilic, K. (2017). A novel Hybrid Genetic Local Search Algorithm for feature selection and weighting with an application in strategic decision making in innovation management. Information Sciences, 405, 18-32.
- 22. Hall, M., Frank, E., Holmes, G., Pfahringer, B., Reutemann, P., & Witten, I. H. (2009). The WEKA data mining software: an update. ACM SIGKDD explorations newsletter, 11(1), 10-18.
Details
| Primary Language | English |
|---|---|
| Subjects | Wearable Materials |
| Journal Section | Articles |
| Authors | |
| Publication Date | June 30, 2019 |
| Submission Date | September 4, 2018 |
| Acceptance Date | May 27, 2019 |
| Published in Issue | Year 2019 Volume: 29 Issue: 2 |