A Simulation Model for Overall Equipment Effectiveness of a Generic Production Line

                Organizations, while managing change, can deploy the tools for change management such as six sigma and TPM (Total Productive Maintenance) to remove redundancies and rework’s elimination. The main objective ofttimes to manage machine or equipment so that it could deliver the most and eliminate the machine downtime completely in all forms. On the other hand, Overall Equipment Effectiveness (OEE) plays a vital role in improving the manufacturing process’s efficiency that, in turn, ensures consistency, quality, and productivity. OEE is of the most common performance evaluation method in manufacturing industries. Further OEE enables key productivity losses’ categorization that occur within the process of manufacturing. OEE, by definition, is a multiplication of performance, quality, and availability that can be calculated by the following formula:

OEE = Performance Quality × Availability

The above three parameters can be further calculated by the following formulas:

This formula is about to find out the performance that is used in any organization to calculate performance. For calculating the performance

The ideal cycle time is divided with the total pieces.

And as from the further calculation it can be seen that the ideal cycle time is equal to the ideal runtime and that is divided by the operating time of the equipment that is used for the production line.

Now calculating the overall performance of the organization and that is equal to the total pieces divided by the operating time and this whole factor is further divided by the ideal runtime.

To find the total quality of the organization and their production line and that is calculated by dividing the good pieces with the total pieces means that by dividing the good pieces from the total pieces the organization can able to find the total quality of their production line.

In the above figure there is discussion about the six major losses to the equipment effectiveness.

In the first part there is formula to calculate the overall equipment effectiveness as well as that is equal to the product of performance availability efficiency plus the third one is the quality.

The six major losses in an organization as well as that are according to losses to equipment effectiveness.

The first two losses are regarding availability plus that includes when equipment is failed so for this if the maintenance manager don’t have the worker when any equipment is failed. When equipment is failed so because of this the production line stops. The second loss regarding the availability is the adjustments and set-ups and if the setup is not good and the production manager don’t have the worker who can able to adjust the machine. If there is no availability of that worker so production line will be stopped.

The next two losses are regarding the failure in the efficiency of performance.

When performance efficiency is weak so this means that production line speed will be reduced.

The next loss in performance efficiency the quality of a production line reduced efficiency.

The last two major losses are regarding to the quality of the production line

When there is no quality in a production line so because of this performance efficiency will be reduced.

The next major loss due to quality is the startup losses and because of this startup loss a quality affects because quality is equal to the good pieces are divided by the total pieces.

In this paper, a simulation model for OEE computation is designed and implemented in this paper. XML files created by multiple criteria-based cost-optimized production lines such as WIP (Work in Progress) inventory minimization, application of Theory of constraint, and idle time minimization are used to derive the input data needed for a model. This means that, these XML lines easily been created through the use of cost optimization production line. Moreover, both fuzzy model and crisp model are compared and implemented in this paper.

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