Reduction of Production Cycle Time by Optimising Production and Non-Production Components of Time in the Metalworking Industry: A Case Study

Abstract

The production cycle (PC) time, as a very important economic indicator of freezing current assets, involves the time needed to manufacture a unit or a series of units, from putting them into production until they are put into storage; and yet it is rarely discussed in the literature, even though it should be also analysed and be made as short as possible. The goal of this article is to survey and control the methodology of reducing the PC time of components in the metalworking industry, grouped by factor analysis into the factors of production and non-production components, observed by a modified method of current observations, and viewed as a process whose effectiveness was monitored using control charts. The survey is based on data collected through 1,576 observations in a Serbian company that manufactures electrical and electronic equipment for motor vehicles. The 2012 results, when compared with those of 2011, indicate that the PC time is significantly reduced by 93 minutes, or by 28.53 per cent, and the manufacturing time by 46 minutes, or by 19.17 per cent. The results furnish empirical findings that provide insights into a number of managerial issues concerning investment decisions in product-specific cycle time improvements and reductions, together with process redesigns. OPSOMMINGDie produksiesiklustyd, 'n baie belangrike ekonomiese aanwyser vir die vries van bestaande bates, behels die tyd benodig om 'n eenheid (of 'n reeks eenhede) te vervaardig, van die begin van produksie tot die stoor van die eenheid. Tog word die produksiesiklustyd selde in die literatuur bespreek. Hierdie artikel ondersoek die opname-en beheermetode van die produksiesiklustyd van komponente in die metaalwerkindustrie, met die doel om dit te verkort. Komponente word gegroepeer deur middel van faktorontleding in produksie en nie-produksie komponente, dit word waargeneem deur 'n aangepaste huidige waarnemingsmetode, en hanteer as 'n proses waarvan die effektiwiteit met beheerkaarte gemonitor is. Die opname is gebaseer op 1576 waarnemings by 'n Serwiese vervaardiger van elektriese en elektroniese voertuigonderdele. Die 2012 resultate, wanneer dit met dié van 2011 vergelyk word, dui aan dat die produksiesiklustyd met 93 minute, of te wel 28.53 persent, verminder het. Die vervaardigingstyd is met 46 minute, dit is 19.17 persent, verkort. Die resultate toon empiriese bevindings wat insig in etlike bestuurskwessies, rakende beleggingsbesluite in produkspesifieke siklustyd verbeteringe en prosesherontwerpe, gee.

Parametric design of a complex part in a FEM environment

“…Since the Tippett's contributions for work sampling in the textile industry, mathematical models for cost reductions from the 1980s [1] to the latest methods as lean principles and techniques, the companies are improving their work methods in order to withstand on the market. Lean principles and techniques constitute a philosophy, having the main purpose and benefits as lower production costs with qualitative output, into a reduced period of time.…”