Intern Report Draft

7/25/2019 Intern Report Draft

1/21

SVKM's Narsee Monjee

Mukesh Patel School of Technology

Management & Engineering, NMIMS

A REPORT

ON

IMPROVEMENT IN OEE BY DECREASEING

CHANGEOVER TIME

BY

SHUBHAM RAJESH TYAGI

COOPER STANDARD AUTOMOTIVE


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A REPORT

ON

IMPROVEMENT IN OEE BY DECREASEING

CHANGEOVER TIME

By

SHUBHAM RAJESH TYAGI

A report submitted in partial fulfillment of the

requirements of 5 years Integrated MBA (Tech)

Programming of Mukesh Patel School of

Technology Management & Engineering,

NMIMS


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ABSTRACT

The exploration for improving productivity in the current global competitiveenvironment has created a need for rigorously defined performancemeasurement system in a manufacturing process. OEE, a vital KPI of TPM isused to evaluate performance and productivity of the machine. OEE is one ofthe performance evaluation methods that are most common and popular inthe production industries. This project tries to improve the OEE index onextrusion machine in organization and identifies the main loss elements in thechangeover process. OEE data on machine performance is an initial key pointto understand the equipment losses and establish improvement to eliminatethem. The results are compared with world class level.

Abbreviations: - O.E.E (Overall Equipment Effectiveness)

T.P.M (Total Production maintenance)

S.M.E.D (Single Minute Exchange of Die)

EXTRUSION (machine)


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INTRODUCTION

Auto weather-strips (weather-stripping) are a crucial part of any vehicle whicheffectively seal the inside of the vehicle and prevent various outside elements

like water, air, dust and noise from entering the vehicle cabin. Now, the mostly

used material for manufacturing weather-strips is EPDM rubber which has

superior resistance to outdoor weather, water, ozone, sunlight, etc. TPE/TPV

and PVC are also used for some parts. With state-of-the-art of manufacturing

and testing equipment, Cooper Standard automotives has grown to be a

leading supplier of vehicle sealing systems and can design, develop and

manufacture nearly all the rubber and plastic weather-strips and trim seals

that contribute to the performance and comfort in a car.

Sealing Capabilities

- Provides extensive vehicle body, door and glass seals extruded fromEPDM (ethylene propylene di-ene monomer M-Class rubber), TPE

(thermoplastic elastomer) and PVC (polyvinyl chloride) that can bereinforced with steel, aluminum and / or wire carriers to provide thebroadest product line-up.

- Leverage of extensive material knowledge to provide the correctdynamic seal solution to meet all of the customer performancerequirements.

- Utilizes TPV (thermoplastic vulcanizate) and PP (polypropylene)seals to reduce weight on products, such as glass runs and wastebelts.

- Has the ability, through its patented process, to provide a one-piececo-extruded assembly with glass run lips integrated below the beltchannel to provide weight savings.

- Fully integrated day light opening trim and seal systems toimprove the vehicle aesthetics and transitions among mating


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components.

- Provides customers with the ability to improve vehicle sealing

aesthetics with uniform appearance.

- Reduces complexity at assembly plants and provides ease ofinstallation and enhanced reliability by offering modular solutions thatare co-extruded with EPDM, TPE and PVC.

- Value added glass run systems available to meet all of thecustomers differentiation requirements and needs.

PRODUCTS

ubber Products Line Card:

rimary Door Seals (mounted on door) Secondary Door Seals(mounted on vehicle body)

indow Glass Run Channels Inner and Outer Belt Weather-strips

indshield Weather-strips, Seals & Gaskets Hood/Bonnet Rubber Seals & Weather-strips

runk/Tailgate Bulb Trims & Seals Sunroof Weather-strips & Seals

ther rubber seals: roof line seals, cowl seals, air conditioning EPDM tube insulation, quarter window seals


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Window glass run channel:

Glass run channel is mounted to insides of the automotive door window frame

and enable movable window glass to slide freely, and also stabilizes the glass

during glass movement and door closing. The rubber channel is covered by

flock or coated with abrasion resistance polyurethane(PU) coating to minimize

friction during movement of the glass.

There are four types of glass run channels

Flocked Glass Run Channel (EPDM Solid Rubber + Flock)Coated Glass Run Channel (EPDM Solid Rubber + PU Coating)Hybrid Glass Run Channel (EPDM Solid Rubber + TPE Slip-coating)TPE-V (TPV) Extruded Glass Run Channel (TPV + Co-extrued on slip-

coating)

Inner and outer beltline weatherstrip:

Beltline weatherstrips are mounted along the beltline of vehicle door

preventing outside weather elements from entering vehicle compartment, and

also stabilize the window glass during its movement. Beltline weatherstrips

have flocked surfaces which help reduce friction and noise.

Material:

PVC+Metal Insert+Flock


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Front and Rear Windshield Weatherstrip:

A windshield weatherstrip surrounds the windshield glass and keep it in place.

Windshield weatherstrips prevent air, water, dust and noise from entering

insides of vehicle cabin.

Material:

1 EPDM Solid Rubber

Hood Weatherstrip:

Hood seals act as sealing barrier between hood and the front portion of

vehicle body.

Material:

1 EPDM Sponge Rubber

2 EPDM Solid Rubber + EPDM Sponge Rubber


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Trunk Weatherstrip/Tailgate Weatherstrip:

The rubber seal(top bulb trim seal) fits into body panel around the trunk and

prevents air, water and debris from entering the trunk compartment.

Material:

1 EPDM Solid Rubber + EPDM Sponge Rubber + Metal Carrier


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PROJECT DESCRIPTION

Detailed study of Extrusion line and study of OEE (Overall

equipment effectiveness) to reduce changeover time of the

operation.

OEE is a highly effective Business Performance Management

Tool, which critically evaluates how effectively a manufacturing

operation is utilized? OEE can be used on single and multiple

production lines and from one to a number of plants in a group-

wide structure. It is suitable for all types of manufacturingprocesses including discrete, continuous or bulk. Put simply

OEE measures the gap between the actual performance and the

potential performance of a manufacturing unit.

AvailabilityAvailability takes into account all events that stop planned production longenough where it makes sense to track a reason for being down (typicallyseveral minutes).Availability is calculated as the ratio of Run Time to Planned Production Time:Availability = Run Time / Planned Production Time

Run Time is simply Planned Production Time less Stop Time, where StopTime is defined as all time where the manufacturing process was intended tobe running but was not due to Unplanned Stops (e.g., Breakdowns) orPlanned Stops (e.g., Changeovers).Run Time = Planned Production Time !Stop Time


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PerformancePerformance takes into account anything that causes the manufacturingprocess to run at less than the maximum possible speed when it is running(including both Slow Cycles and Small Stops).Performance is the ratio of Net Run Time to Run Time. It is calculated as:Performance = (Ideal Cycle Time "Total Count) / Run Time

Ideal Cycle Time is the fastest cycle time that your process can achieve inoptimal circumstances. Therefore, when it is multiplied by Total Count theresult is Net Run Time (the fastest possible time to manufacture the parts).Since rate is the reciprocal of time, Performance can also be calculated as:Performance = (Total Count / Run Time) / Ideal Run Rate

Performance should never be greater than 100%. If it is, that usually indicatesthat Ideal Cycle Time is set incorrectly (it is too high).

QualityQuality takes into account manufactured parts that do not meet qualitystandards, including parts that need rework. Remember, OEE Quality issimilar to First Pass Yield, in that it defines Good Parts as parts that

successfully pass through the manufacturing process the first time withoutneeding any rework.Quality is calculated as:Quality = Good Count / Total Count

This is the same as taking the ratio of Fully Productive Time (only GoodParts manufactured as fast as possible with no Stop Time) to NetRun Time (all parts manufactured as fast as possible with no stoptime).

OEEOEE takes into account all losses, resulting in a measure of truly productivemanufacturing time. It is calculated as:OEE = Availability "Performance "Quality.

If the equations for Availability, Performance, and Quality are substitutedin the above and reduced to their simplest terms the result is:


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OEE = (Good Count "Ideal Cycle Time) / Planned Production Time

This is the simplest OEE calculation described earlier. And, asdescribed earlier, multiplying Good Count by Ideal Cycle Timeresults in Fully Productive Time (manufacturing only Good Parts, asfast as possible, with no Stop Time).

TASK ALLOTTED

Changeoveris the process of converting a line or machine from

running one product to another. Changeover times can last from a few

minutes to as much as several weeks in the case of automobile

manufacturers retooling for new models. The terms set-up and

changeover are sometimes used interchangeably however this usage is

incorrect. Set-up is only one component of changeover.

Clean-up

Cus product, materials and components from the line. It may range fromminor, if only the label of a package is being changed (for example from anEnglish to a Spanish label) to major, requiring complete disassembly of theequipment, cleaning and sterilizing of the line components in the case of an

injectable pharmaceutical product.

Set-up

Set-upis the process of actually converting the equipment. This may beachieved by adjusting the equipment to correspond to the next product or bychanging non-adjustable "change parts" to accommodate the product.Typically, it will be a combination of both.

Start-up

Start-upis the time spent fine tuning the equipment after it has been

restarted. It is characterized by frequent stoppages, jams, quality rejects

and other problems. It is generally caused by variability in the clean-up

and set-up or by variability in the product or its components.


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SIX BIG LOSSES IN MANUFACTUING PROCESS

SIX BIG LOSS

CATEGORY

OEE LOSS

CATEGORY

EVENT EXAMPLES

W.R.T

EXTRUSION

PROCESSBreak Downs Down Time Loss Die changing

Equipment Failure

UnplannedMaintenance

Setup and Adjustments Down Time Loss Setup/changeover

Extruder Shortages

Unskilled operator

Warm-up TimeSmall Stops Speed Loss Cleaning

Sieve Blocked

Temperature settingsReduced Speed Speed Loss Equipment Wear

Under Designcapacity

Start-up Rejects Quality Loss Scrap

Reworks

Printing Problems

Length Variations

Production Rejects Quality Loss Scrap

Rework

Texture Change

TIME STUDY:

A work measurement technique for recording the time and rate of worker

for the elements specified to carry out a job under different conditions or

under specified conditions for analysis of data so as to determine the time

necessary to carry out a job at a defined level of performance.


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OBJECTIVE OF TIME STUDY

- Comparing alternative methods

- Planning and controlling- Delivery date of product from a complete manufacturing system- Cost reduction and cost control- Elimination of scrap

STEPS INVOLVED IN MAKING OF TIME STUDY:

1) SELECT: Selection of manufacturing line.

2) OBTAIN AND RECORD:Details and study about the methods,operator, job and working conditions

3) DEFINE:Defining the manufacturing line and breaking the line intosmaller elements for detailed study

4) MEASURE:Measure the time duration of each element and then giveperformance rating

5) EXTEND:Observe time into normal time

6) DETERMINE:Determine different allowances given to a worker

7) COMPUTE:Compute standard time for the manufacturing line andother standard values.

Reduction in changeover time by analyzing the changeover activities

and detecting sources of errors causing increase in the changeover

which ultimately increases the machine uptime.


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Below is shown a real time example of changeover activities and

time spend in doing them.

(READINGS ARE TAKEN IN COOPER STANDARD AUTOMOTIVES

PVT.LTD)

Time study done on Extrusion Line No:6 (using stop watch)

Previous Profile : Nissan Glass run BB

Next Profile: Nissan Glass run CC

Man Power :5

Change over Start Time: 16:00

Last Ok product of previous profile: 16:07

First Ok Product OF next profile: 16:40


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METHODS INVOLVED IN REDUCING CHANGEOVER:

SMED (Single Minute Exchange of Die)

Single Minute Exchange of Die (SMED), or Fast Changeover, is as thename suggests the method by which equipment can be changed from oneproduct to the next in the most effective way, and in the shortest possible time.

Single Minute Exchange of Die is an objective whereby all changeovers

are completed in a single number of minutes (less than 10). S.M.E.D. is

an integral part of T.P.M. (Total Productive Maintenance)


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KEY STEPS FOR DECREASING CHANGEOVER TIME

- Identifying and selecting a process improvement team consisting of bestsetup/machine operators that are able to identify and separate internaland external steps

Starting with current state - selecting and focusing on onemachine

Walk-through the entire setup process, in detail, and recordingthe steps in written or video format

Identifying detailed internal setup steps as these require themachine to stop

Example:Removing a die from a Extruder machine.

- Identifying detailed external steps- steps that may be performed asthe machine is running

Example:Obtaining the die required for the next job while the currentjob is in progress

- Separating the work while the machine is stopped in order to categorizeeach activity as either internal or external

- Converting internal steps to external steps

- What external steps of the setup process are being treated asinternal steps? Example:Planning every day and communicatingwhich machines will require setups, and calculating approximatelywhen they will take place

- Preparing dies, tooling, and materials outside of the department

(tool room) while the current job is still running.


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- Reducing remaining Internal Work

Working with machine operators and setup people for betterunderstanding of what their challenges are.

remove these barriers so they focus more on fast changeoversrather than performing non-valued added tasks

- Creating improved setup/changeover process

Capturing and analyzing accurate setup data, then focuing on thesteps wasting the most time

Asking operators for their thoughts

- Training all operators/setup people in the new process

Clearly labeling, organizing, storing, and maintaining all tooling tominimize surprises

Using dowels or go-no go fastening systems to eliminate

adjustments in the first place, ensuring tooling is cleaned andmaintained as it is returned to its stocking location after previoususe


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REFERENCES:

- Cooper Standard automotives product catalogue

- Cooper Standard automotives HR manual.

- Wikipedia

- Oee.com

- Activity data sheet. (self prepared)

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