Smart Oee-Sigma Model for Production Process Optimization

Abstract

The quest for effective utilization of both humans and machinery is on the increase in order to survive competition. Overall Equipment Effectiveness (OEE) metric application in industry has been facing a challenge of continuing advancement in industrial operations. A smart OEE is required for a quick response to the dynamism in industrial system. In this study, OEE metric is made smart by integrating sigma continuous improvement tool into it for the enhancement of dynamism required of the traditional OEE model measured basically on three factorsavailability, performance and quality. System productivity dynamism is measured and predicted through sigma statistical variation of the production process defined as a ratio of delivered output (supply) to the expected (planned) output. The model was applied to a production process of fast moving product. The results obtained for the seven consecutive years (2006 to 2013) for traditional OEE are 100%, 92%, 84%, 86%, 89%, 81%, and 84%, respectively. In the new OEE-Sigma method, productivity can be continuously improved over the years by at most 77%. This indicated that smart OEE-sigma model is a better tool for enhancing continuous improvement in a dynamical processing environment.Pametan OEE-sigma model za optimizaciju procesa proizvodnje. Potraga za efikasnom upotrebom kako ljudi tako i mašina je u porastu kako bi preživeli konkurenciju. Primena metričkih efekata na ukupnu efikasnost opreme (OEE) u industriji je pred izazovom stalnog napretka industrijskih operacija. Pametni OEE je potreban za brz odgovor na dinamiku u industrijskom sistemu. U ovoj studiji, OEE metrika je napravljena pametnom integracijom sigma kontinuinualnog alata za poboljšanje njega kao i poboljšanje dinamičnosti koja se zahteva od tradicionalnog OEE modela koji se meri u osnovi na tri faktora -dostupnost, performanse i kvalitet. Dinamika produktivnosti sistema se meri i predviđa sigma statističkom varijacijom proizvodnog procesa definisanog kao odnos isporučene proizvodnje (ponude) i očekivanog (planiranog) izlaza. Model je primenjen u procesu proizvodnje proizvoda koji se brzo kreće. Dobijeni rezultati za sedam uzastopnih godina (od 2006. do 2013. godine) za tradicionalne OEE su 100%, 92%, 84%, 86%, 89%, 81% i 84%, respektivno. U novoj OEE-Sigma metodi, produktivnost se može kontinuirano poboljšavati tokom godina za najviše 77%. Ovo je pokazalo da je pametni OEE-sigma model bolji alat za poboljšanje kontinualnog poboljšanja u dinamičkom okruženju za obradu. Ključne reči: Smart OEE, Sigma metrika, kontinualno poboljšanje, proizvodni proces AKNOWLEDGEMENT BAT company Nigeria is acknowledged for allowing the collection of necessary information used in this study.

Determination of Production System Effectiveness Based on Sustainable Global Standards

“…For industry 0.1 ≥ 1, it is expected that time losses due to failure / idle time should not exceed the minimum range of Availability, Performance, and Quality as established, in past studies [3], [38]. i.…”

“…Efforts and programs targeted at improving productivity in Nigerian industries have not yielded significant results [3]. The distribution of labor productivity by age of firms reveals that an average productivity of NGN10, 198 per worker is recorded among firms above 20 years of age and that labor productivity increases with the firm's age [4].…”

“…Sustainable development also means attaining a balance between environmental protection and human capacity building and between present and future needs [8]. In all cases, manufacturing (production) industries played a very important role in achieving a sustainable development goal by 2030 [3].…”

“…Excessive waste generation has made entrepreneurs find it difficult to break even. The development of a dynamic error-proof Overall Equipment Effectiveness (OEE) model for optimizing the operations of a complex production system is targeted at minimizing/eradicating generated wastes/losses [3].…”