1 . ADVANTAGES
As mentioned in earlier chapters, Lipton stock consists of 2 types of tea hand bags production machines. The " Constanta" and " Perfecta" machines. The average overall products effectiveness (OEE) for those devices is 70 percent, This is due to the large OEE Ideal machines which can be approximately means 88, 7%. This excessive OEE compensates the low OEE for Constanta machines that has an average of 64. 7%. A minimal OEE in Constanta lines means low valuable moment for producing teabag boxes and thus lost revenue opportunity. In this chapter emphasis will be about addressing the challenge with Constanta lines. First the OEE of Constanta lines was calculated. In that case, to address the main causes behind that low OEE, a Root cause examination was carried out, all this will be explained in details.
1 . ADVANTAGES
According to previous chapters, Lipton manufacturing plant consists of 3 types of tea development machines. The " Rolla Trainer" machine for development of box tea, " Constanta" & " Perfecta" machines equally for the production of tea bags. The regular overall equipment effectiveness (OEE)for three types of devices is 86. 2%, The main reason for this is the high OEE for both equally Perfecta & Rolla Trainer machines which usually ranges coming from 85-95%. This kind of high OEE compensates the lower OEE for Constanta devices which has an average of 64. 7%. This chapter focuses on the causes behind Constanta machine's low OEE as well as its parameters. To address the problems due to obsolete Constantas two strategies were carefully considered:
-A thorough comparison among Constanta and perfecta devices is available to prove so why Perfecta is the most suitable replacement for obsolete Constanta from various perspectives. -- Replacement research: This analysis considers changing some of the cheapest OEE Constanta machines with a more advanced equipment which is the perfecta. This analysis is actually a numerical comparison between each type of machine's: -Marginal costs
-Equivalent uniform annual cost (EUAC)
This technique determines the economic lifestyle for ideal and establishes the exact year upon which Constants must be substituted. In addition to determining the economic lives through replacement analysis, A great excel version is also one of them chapter to choose the total quantity of machines required for both types to fulfill the annual embrace the market demand forecasted for the coming your five years. This model takes into consideration several constraints and considers the objective function from an expense minimization perspective. Last but not least, One final indicator of success of both of the previous steps, the replacement research and the exceed model which usually both suggests that replacing a certain number of Constants for Perfectas, The payback period solution which determines the length of time needed to retrieve the amount of capital invested in purchasing the Perfecta machines. The Repayment period is a crucial indicator of weather the effect of the previous steps is feasible to the factory or not.
2 . COMPUTING OEE OF COSTANTA LINES
Table() and Table() illustrate the calculations required for determining the average OEE of Constants (64. 7%). These dining tables are taken out from the factory's control system SCADA which automatically figures the ideals for all elements related to OEE parameters that are as mentioned before, Availability, Performance and Quality decide the average worth of OEE automatically simply by multiplying the values with the three variables as displayed. The factory runs 19. five hours/day, 26 days/week, hence the Loading Time /month = 19. 5*26= 507 hours/month Table()
Reloading Time(hrs)| 507
Gear Breakdown| 13
Cutting cutting tool change| one particular
Management | 1
Functional Motion| six
TOTAL DOWNTIME LOSS| twenty-five
Operating Time| 482
Minor Stoppages| 97
Series Organization| 15|...