The diploma work deals with measurement of Production Overall Equipment Effectiveness in manufacturing company Alfa. Firstly, is processed the theoretical part concerning general production, TPM, lean manufacturing and OEE. After than is described the company, monitored device and technology used by the device. In the final section is evaluated the OEE for January, February and March; analyze downtimes, mistakes and losses and their solutions are proposed. The last chapter is devoted to the economic evaluation of the proposal.

Master thesis is focused on the study of effectiveness of selected machines in the company through indicators of Overall Equipment Effectiveness. The aim is to increase productivity of machinery by monitoring machine run. Analyses are performed on selected machines which are found out downtimes reducing machine run. Methods and tools of lean manufacturing are used for determine downtimes as a core part. Specifically, the implementation of the first phase of TPM – “Total Productive Maintenance” which is used in manufacturing, for determine current status of machines. Maintenance of machinery is also referred in the master thesis as important part of Overall Equipment Effectiveness. Individual factors of OEE are identified as a result of these analyses which are directly affected to productivity of machines. The output of these analyses is to design countermeasures against each downtime and system design of monitoring tools including technical and economical evaluation. Machine monitoring with automatic data collection based on calculated data is suitable option for the company.

This thesis investigates the possibility to adapt Overall Equipment Effectiveness (OEE), tothe development process in the shipbuilding industry.More specifically the development process wasdelimited to the phases; design, work preparation, production and verification.Ordinarily, OEE is a performance measurement for mass production. Itincludes aquality parameter which has been the focus of this thesis. Both literature review and case study investigation show that process quality is of critical importance in the shipbuilding industry because of the needs for dimensional accuracy and high-quality assemblage.The three main factors affecting process quality are;the flow of information between engineering phaseand productionphase, and the amount of rework and delays. The factors wereevaluated along an optimization method with a specific attention to process quality. Acase studywas conductedto confirm the relevance of the literature review on factors affecting process qualityand allowedto gather factors in process quality that are relevant to the industry.In light of those results, I re-developed a model providingnew measurement of what I call OPQE (Overall Process Quality Efficiency).This study contributes to a betterunderstanding of process quality in ETO(Engineering-To-Order)industries. Notably it shows how deviations that require rework and causesdelays are impacting process quality. It also shows that detecting errors early in the process of production is essential for insuring quality control. An error detected late affects negatively process quality and increases cost.

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This report includes a thesis in an advanced level and includes 30 credits in the subject product development. The work consist of a case study performed at Gnutti Carlo AB in Kungsör. The work has been carried out by a student from Mälardalen University spring term in 2016.In the manufacturing process in cell 1, there is a bottleneck problem due to various factors, which disrupt production that resulted in a loss of time. Gnutti Carlo AB Company has started a project where the goal is to let the manufacturing process work at full capacity, which it does not do today.The goal of the project work is to develop a solution that increases the capacity of the manufacturing process by raising the OEE value from 78,33% to more than 95%. The project is carried out by following the product development process as presented by Ulrich & Eppinger's book. Various tools were used in this process to help the author obtain the final solution.A case study was conducted to solve the research question; how can the capacity of the manufacturing process be increased where the bottleneck problems arise? Based on the guidelines that have been assigned by the supervisor, various interviews and own investigations, a basis for the formulation of the problem was formed.The main problem was divided into four problems with the aim to be resolved through the development and evaluation of ideas in every area of concern to then combine the various ideas to several concepts, which in turn were examined and evaluated in order to select the concept that became a useful solution.Based on the main issue, a concept has been developed which in theory answers how the capacity of the manufacturing process was increased. Through eliminating the time losses in the process, the capacity in the manufacturing process increased by 98.5% of a continuous OEE, which is both higher than the target of OEE 95% and the present 78.33%. The solution consists of a 3D Camera that analyses all the details in the pallet while it is moved by a cylinder. These are mounted in a frame that is made with square pipes.To ensure that the final solution could cope the stresses of the construction it was tested by examining the sustainability of the solution. FEM analysis was performed in SolidWorks that showed where the highest stresses are, to ensure that it can cope with the forces that are weighing on the solution. The components that were investigated got safety factors 64 and 114.

Made available in DSpace on 2016-06-23T12:15:51Z (GMT). No. of bitstreams: 2 12.pdf: 3444028 bytes, checksum: 73c0e8984bffa4bb547494ec30407d6f (MD5) license.txt: 1748 bytes, checksum: 8a4605be74aa9ea9d79846c1fba20a33 (MD5) Previous issue date: 2013 / Made available in DSpace on 2016-07-05T22:37:59Z (GMT). No. of bitstreams: 3 12.pdf.txt: 204813 bytes, checksum: 9eae4f603bf69f1c3e4907b919ce4332 (MD5) license.txt: 1748 bytes, checksum: 8a4605be74aa9ea9d79846c1fba20a33 (MD5) 12.pdf: 3444028 bytes, checksum: 73c0e8984bffa4bb547494ec30407d6f (MD5) Previous issue date: 2013 / A concorrência no setor farmacêutico é intensa e os produtos farmacêuticos possuem tempo de ciclo reduzido quando comparado com os grandes investimentos de P&D. Para concorrer neste setor, as indústrias estão sempre com foco em melhorar a eficiência dos processos de manufatura utilizando muitas vezes equipamentos complexos, modernos e automatizados com foco na produção para atingir as metas. Neste contexto, o objetivo deste trabalho é demonstrar o melhor controle da produção utilizando como base a metodologia de Manutenção Produtiva Total da Produção buscando a maximização da eficiência dos equipamentos e recursos disponíveis, utilizando várias ferramentas dentre elas a Overall Equipment Effectiveness (OEE) conhecida como eficiência global dos equipamentos de produção. Esta ferramenta permite monitorar o desempenho da linha de produção, identificar os principais gargalos, monitorar os índices de OEE, sugerir ações de melhoria no processo. Na análise de resultados do OEE ficou evidenciado que os setups, troca de máquina, representavam grandes desperdícios ao processo produtivo sendo então utilizado o SMED para redução destes tempos e conversão em tempos reais de produção. Também a utilização e implementação de outras ferramentas de apoio à implementação, manutenção e sustentação da produtividade como: trabalho padrão, análises de causa-raiz, guia de solução de problemas, criação de um conselho de OEE, educação e treinamento, Gemba, Kaizen, 5 s, trabalho padrão para liderança, controles visuais, reuniões de níveis de responsabilidade baseadas no sistema lean de gerenciamento de produção (Tier 1, Tier 2, Tier 3 e Tier 4). O conjunto destes resultados acaba aumentando o lucro, a produtividade e qualidade, reduzindo assim os custos para o setor farmacêutico possibilitando maior competitividade. Neste estudo ficou possível observar que com a implementação destas ferramentas de gerenciamento da produção transformou-se desperdícios envolvidos no processo em tempo real de produção. / The competition in the pharmaceutical industry is intense and the products have reduced life cycles when compared to the large investments in R&D. To compete in this sector is necessary to improve the efficiency of the manufacture processes often using complex, equipment, modern and automated with focus in the production to reach the goals. In this context, the objective of this work is to demonstrate better control of production basis in the use of Total Productive Maintenance seeking to maximize the efficiency of equipments using various tools among them the Overall Equipment Effectiveness. This tooling allows you to improve the acting of the production line, to identify the bottle mouths, monitor OEE index, and suggesting improve actions in the process. Related the results of OEE analysis have been demonstrated that setup represented major wast in the production process so that the tooling SMED was used to reduce the time of change on the machine and convertion on the productive time. Beyond use of OEE another tools are used to support the implementation, maintenance and support the productivity as standard work, root cause analysis, troubleshooting, creating of OEE Council, education & training, gemba, Kaizen, 5 S, leader standard work, visual control, tier accountability based on the Lean Methodology (Tier 1, Tier 2, Tier 3 and Tier 4). The group of these results ends up increasing the profit to the productivity, quality, and cost reduction to the pharmaceutical industry enabling greater competitiveness. In this study was possible to observe the implementation of managament production tooling that’s convert waste time in an production real time.

Diplomová práce se zabývá problematikou zvyšování produktivity pomocí metody štíhlé výroby zvané Lean. V dnešní době je potřeba udržet si přízeň zákazníka a finanční prosperitu firmy. Právě štíhlá výroba se zaměřuje na spokojenost zákazníka a na zvýšení finančního přínosu firmě, tím, že se snaží odstranit plýtvání, která se vyskytují v procesu. Lean Six Sigma je metoda, která se zaměřuje na spokojenost zákazníka (Lean) a na zdokonalování procesů (Six Sigma). Jejím cílem je zvýšit kvalitu a zároveň snížit náklady a dobu dodání. První část diplomové práce se zabývá nástroji štíhlé výroby a detailně popisuje metody, které budou použity v praxi. V praktické části diplomové práce byly využity nástroje Lean Six Sigma především metoda DMAIC, která je označována za systematický přístup k řešení problémů. Skládá se z pěti částí: definování, měření, analýza, zlepšení a kontrola.

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The purpose of this thesis is to implement Total Productive Maintenance (TPM) in Nigeria Plastics Manufacturing Company. Manufacturing companies round the world pay huge amount of money for purchasing new equipments to boost their production however nothing or little is done to achieve or obtain full output from the machine for which it is intended to do. Small losses in time or deviations from planned or calculated capability are taken as usual machine performance. But currently as a result of improved capability levels and demand of quality product at lower prices, purchasing latest machine/equipment is not a way out unless it is completely used. Total Productive Maintenance (TPM) is a method that involve everybody totally, from high management to all workers to implement a complete maintenance program for all machine/equipment during its life. This method ends up in most effectiveness of tools, equipment, virtuously improved workers, tidy up working area, neat and clean working environment. A structure is going to be developed with the potential of evaluating the impact of implementing total productive maintenance within. By evaluating the result or outcome of Total Productive Maintenance (TPM), manufacturing companies can create sensible/smart decisions to improve the potency and standard of the machine, equipment and also the product on XYZ Plastics Manufacturing Company in Nigerian.

The theoretical part of this master’s thesis introduces to the reader problems of production management tools, and optimization of the manufacturing process. It explains basic concepts, principles and methods that has aim to clarify systems and methods used in the practical part to the reader. The practical part describes the implementation of these methods and optimization of specific part of the manufacturing process. The result of optimization is evaluated from the perspective of time and finance.