What methods can you use to evaluate manufacturing process efficiency?

Cycle Time ??? study methods are vital for evaluating manufacturing process efficiency. They offer a detailed view of workflow, pinpoint bottlenecks, aid in setting targets, and foster data-driven improvements, driving enhanced efficiency in production.

Cycle time vs Takt time this comparison is very important from the organization point of view to achieve the demand. To achieve 100% on time demand cycle time should always be less than Takt time. Cycle time - Time taken to complete the product or process from start to end . Takt Time - its the time derived from the demand and the time available. Takt time is governed by demand/requirement of product or process. Cycle time - is combination of Value added and Non value added activities. efficiency can be monitored by Value stream mapping , which tell you that what amount of NVA are there in the system.

We can use some method to evaluate the manufacturing process efficiency : 1- OEE 2- Cycle time analysis 3- Through put & capacity analysis 4- Lean manufacturing principles

Before optimization, the cycle time for the entire assembly process might have been, for example, 15 minutes. After implementing improvements, the cycle time could be reduced to 10 minutes, resulting in a 33% improvement in efficiency. Cycle time analysis can be applied in various contexts beyond manufacturing, such as software development, service industries, and healthcare. The key is to identify the specific process, measure the time at each step, and then use the insights to make informed decisions for optimization.

Like most, I would put OEE first. This shows you the value to the organization. Further to that, I would encourage you to read Drew Troyer's articles on Overall Business Effectiveness (OBE). Cycle Time Analysis, Value stream mapping, SPC, and (yech) Lean Six Sigma, are all secondary to this analysis.

In my experience the most difficult part of OEE is getting unbiased, accurate data for calculating OEE for discrete assembly lines. There are always some inputs which require operators to record the data. Even on highly automated data collection systems there are still some manual methods required to account for downtime reasons. Operators have to be properly trained what OEE is & why it is important to track it accurately. There must also be an element of trust established between operators & management.

It is also important when creating the parameters for your OEE you take into account stoppages for maintenance, cleaning and autonomous care. All too often i see low figures which have been computer generated which just dont take this into account. Suffer the half hour loss for cleaning and an AC routine or there will be a 3 hour breakdown coming your way.

The formula for Overall Equipment Effectiveness (OEE) or Overall Plant Effectiveness (OPE) is based on the following factors: total production, number of shifts, line cycle time, available time, losses incurred, effective available time and effective production time. By calculating these factors, we can get a realistic measure of OEE/OPE. The management should determine the efficiency level (90% or 95%) that they want to use for OEE/OPE calculation.

OEE é a melhor forma de se medir a eficiência de um processo produtivo. O ponto principal de aten??o é garantir a confiabilidade dos dados coletados e/ou registrados para que seja feito o cálculo. Dados inconsistentes, excesso de inputs manuais sem critério claro, fazendo-se valer da subjetividade, tiram a credibilidade desse KPI t?o vital para a gest?o da produ??o. Precisa-se buscar formas de automatizar o máximo as coletas, de preferência em tempo real.

OEE gives a complete picture of manufacturing effectiveness. Line availability, input part quality and through put. OEE of 85% or more is standard in the automotive manufacturing line.

Material and information flow are a key element of VSM. Having the folk create the VSM who understand the current process and all it challenges is key. It’s eye opening once you lay it out just how much opportunity exists.

Creating an end-to-end VSM of your process is eye opening. It not only grants you a deep understanding of what truly takes place within the process but also fosters collaboration and enhances visibility of work and workflow across individuals and departments. People may believe they know how a process operates, but won’t see the full picture until they invest the time to map it out. The VSM process prompts lots of great questions while exposing waste and chaos. Developing a future state map for the process then drives creativity and collaboration, ultimately resulting in a unified direction that people can move towards by experimenting and implementing new ideas.

Value Stream Mapping is a powerful methodology that contributes significantly to the evaluation and enhancement of manufacturing process efficiency. By visually representing the entire production process from raw materials to the delivery of finished products, VSM provides a comprehensive overview. This mapping technique helps identify both value-adding and non-value-adding activities, enabling manufacturers to streamline operations. VSM allows for the identification of bottlenecks, delays, and redundancies in the process, facilitating targeted improvements. It aids in understanding the flow of materials and information, promoting smoother logistics and reducing lead times.

O VSM é uma ferramenta que se usada corretamente se torna uma poderosa arma na busca da eficiência. Desperdícios relacionados ao Motion e tempo de espera s?o comuns, porém n?o s?o t?o perceptíveis dentro das rotinas. Ao identificar uma situa??o de excesso de Motion dentro do processo, pode-se corrigir usando o Spaguetti Chart. No caso do tempo de espera aguardando matéria prima ou sub conjuntos vindos do estoque, deve-se avaliar a utiliza??o do Water Spider.

Value Stream Mapping (VSM) should always be the first step when evaluating the efficiency of any process. A complete VSM allows you to see the flow of goods and the data associated at each step of the process to bring goods to the customer. This data then can be used to determine how efficiently the process is currently performing. When combining with other lean tools, the VSM can help you determine the issues of areas of improvement in the process as well as create and plan to achieve your ideal future state VSM of the process

Statistical Process Control (SPC) is a vital methodology in evaluating manufacturing process efficiency by providing a systematic approach to monitor and control production processes. Through the use of statistical techniques, SPC helps manufacturers detect variations and deviations from the established standards during the production cycle. By collecting and analyzing data at various points in the process, SPC allows for the identification of trends, patterns, and potential issues that may affect efficiency and product quality. It enables real-time monitoring, ensuring that the manufacturing process stays within predefined control limits. SPC not only identifies anomalies but also aids in understanding the root causes of variations.

SPC is important to evaluate how well your process is capable of meeting the given specification. Through data collection, we can calculate, through statistics, relationships between input and output variables and seek the best model for the process.

O cep pode mostrar muito claramente as tendencias de varia??o e descontrole de processos. Porém é muito importante nos atentarmos ao metodo que esta sendo utilizado na medi??o pois dados errados levarao a analises erradas e possivelmente em vez de melhorias teremos pioras no processo

O Controle Estatístico de Processo proporciona antecipar e prevenir rupturas na cadência produtiva através da análise de tendência do processo dentro dos limites de especifica??o. Normalmente tratar os desvios ainda na fase de controle é mais rápido, eficaz e menos custoso. Em adicional, evita-se paradas maiores, retrabalhos, segrega??o de lotes e refugos.

Statistical Process Control (SPC): SPC involves using statistical data and control charts to monitor and control the manufacturing process. By analyzing process variations, manufacturers can identify trends, deviations, and out-of-control conditions that can impact efficiency. SPC helps in implementing real-time adjustments and corrective actions to maintain process stability and improve efficiency.

Six Sigma is a systematic approach for identifying & eliminating waste (non-value-added activities) in the process through continuous improvement by flowing the Product/Service at the pull of customer. Six Sigma Projects is based on 2 methodologies - DMAIC and DMADV. a) DMAIC - Define, Measure, Analyse, Improve, Control DMAIC should be used when a product/process is in existence at your company but not meeting customer specifications or not performing adequately. b) DMADV - Define, Measure, Analyse, Develop, Verify. DMADV should be used when a product/process is not in existence in the company & needs to be developed or The existing product/ process exists & has been optimized & still doesn't meet the level of customer specification.

I believe the LSS methodology to be the best approach. Combining Lean which targets eliminating waste and focusing on flow and SS which targets variation and focus on problem solving, combines the two elements that will drive improvement in efficiency, reduce total cycle time and reduce variation leading to better performance on customer satisfaction and cost. VSM, OEE, SPC, etc. are tools to be used in LSS methodology.

O Lean Six Sigma conseguiu unir duas metodologias de forma simples e eficaz, facilitando o paradoxo que existia em se escolher uma ou outra. O Lean é muito útil para a redu??o das perdas e desperdícios, enquanto o Six Sigma é fundamental para quando desejamos reduzir a variabilidade do processo dentro dos limites superior e inferior de especifica??o, tornando-o mais capaz (Cp e Cpk). A utiliza??o combinada traz ganhos rápidos e eficientes dentro do processo.

Lean Six Sigma, a powerful methodology combining the principles of Lean Manufacturing and Six Sigma, is instrumental in evaluating and optimizing manufacturing process efficiency. The Lean aspect focuses on eliminating waste and non-value-added activities, streamlining processes for increased efficiency.It emphasizes reducing variations and defects, ensuring consistent and high-quality outputs. Together, they provide a holistic approach to process improvement. Lean Six Sigma employs data-driven analysis to identify areas of improvement, enhance productivity, and eliminate inefficiencies. Through tools such as DMAIC (Define, Measure, Analyze, Improve, Control), it enables a structured and systematic evaluation of manufacturing processes.

Lean Six Sigma serves as a powerful tool in evaluating manufacturing process efficiency. It combines waste reduction, data-driven decision-making, structured methodologies, and a culture of continuous improvement, driving substantial enhancements in efficiency, quality, and overall performance. Lean Six Sigma provides a structured approach. It employs DMAIC (Define, Measure, Analyze, Improve, Control) or DMADV (Define, Measure, Analyze, Design, Verify) methodologies, offering a systematic framework to evaluate, analyze, and improve manufacturing processes.

Based on tools like cycle time, VSM, OEE, Six Sigma, SPC, etc we can identify the current situation and see where we are in respect to planned, But in actuality we should be able to understand from the current situation with data on parameters of Man, Machine, Method, Material, Money, Moral, Time / delivery & Quality in terms of bottlenecks - to act on these impediments to make better efficient & effective product.

- Create a daily JPH (jobs per hour) monitoring board to track the production performance and efficiency - Identify the losses that affect the JPH, such as defects, rework, downtime, etc. - Create Pareto Charts for NVA's (non-value added activities) to prioritize the most significant losses and eliminate waste - Perform Root Cause Analysis of losses or breakdowns using tools such as 5 Whys, Fishbone Diagram, etc. - Implement Preventive & Corrective actions for respective losses identified and assign responsible person to take action - Monitor HPU (hours per unit) to measure the labor productivity and utilization - Motivate the operators by providing feedback, recognition, incentives, training, etc.

Creio que podemos adicionar algumas medi??es que facilitam o controle do processo produtivo: UPH/DL - Units per hour / direct labor, onde avaliamos a eficiência da produtividade perante a quantidade de colaboradores diretos que s?o necessários para determinado volume de produ??o. Pode-se variar com outras unidades métricas como litros por hora, toneladas por dia, etc.

MQC Manufacturing Quality Control regular auditing. Effective Toyota practice., and PDCA. Plan Do Check Action is a basic rule.

There are few others also like first pass yield , operator efficiency, an element of COPQ etc which can help to monitor manufacturing efficiency.