Elevado, John Christian I. Engr.

Luigi Sandoval

IE 4-1

Sr. No. Category Before After

1 Shift Time 720min 720min
2 Total Production in a shift 160 Nos. 160 Nos.
3 Scheduled Break 50min 50min
4 Non Scheduled Break 5min 0min
5 Breakdown 4min 0min
6 Cleaning, Inspecting & 15min 15min
Tightening of inserts
7 Operator Absent 55min 6.5min
8 Non Conforming Product 5 Nos. 3 Nos.
9 Theoretical Cycle Time 3min 7.5min
10 Availability (A) 0.90 0.98
11 Performance Efficiency 0.73 0.85
(PE)
12 Quality Rate (QR) 0.96 0.95
13 OEE (A × PE × QR) 0.63 0.79

Percentage Improvement:

Category Before After Increase % Increase

Shift Time 720min 720min 0 0
Total Production 160 Nos. 160 Nos. 0 0
in a shift
Scheduled Break 50min 50min 0 0
Non Scheduled 5min 0min 5 100
Break
Breakdown 4min 0min 4 100
Cleaning, 15min 15min 0 0
Inspecting &
Tightening of
inserts
Operator Absent 55min 6.5min 48.5 88.18
Non Conforming 5 Nos. 3 Nos. 2 40
Product
Theoretical Cycle 3min 7.5min 4.5 150
Time
Availability (A) 0.90 0.98 0.08 8.89
Performance 0.73 0.85 0.12 16.44
Efficiency (PE)
Quality Rate 0.96 0.95 0.01 1.04
(QR)
OEE (A × PE × QR) 0.63 0.79 0.16 25.4
Recommendation:

 Strict implantation of 5S to reduce waste in all fields of work is a must this can increase
efficiency, reliability and productivity of the whole system. Planning Maintenance ahead
of time is a must for the operations to adjust and be ready to all possible contingencies
inside and outside of the system or workplace. Following Safety and Health Standards
also improve productivity in such way that all employees has this sense of security inside
the organization and thus can perform their respective tasks well.

 Equipment Effectiveness will also rise given the said improvements for the reason that
there will be less downtime due to proper maintenance procedure and maintenance
scheduling.

 A full support from the top management plays a big role in such changes and
improvement. Top management people should really assess the pros and cons of a
proposed improvement plan without being bias to any party or personal interest.

QC Tools that are vital for such improvements:

Cause-and-effect diagram (also called Ishikawa or fishbone diagrams): Identifies many possible

causes for an effect or problem and sorts ideas into useful categories.

 Vital for the reason of finding the true cause of the bottleneck and problem in the
system whether if its caused by human, machine or the whole workplace. Finding the
root cause of a certain problem can contribute alot in obtaining the optimal
enhancement or improvement of a system.

Check sheet: A structured, prepared form for collecting and analyzing data; a generic tool that
can be adapted for a wide variety of purposes.

 Check sheets are important for monitoring and making sure all actions that has been
conducted is under the protocols of safety and improvement. It is a clear list of things
that has been done or has to be done in order for a system to be properly maintained or
improved.

Histogram: The most commonly used graph for showing frequency distributions, or how often
each different value in a set of data occurs.

 Histogram shows clearly what is happening on a certain process or machine in the past .
it can be use as a basis for future improvement in terms of output and the likelihood of
failure.
Pareto chart: A bar graph that shows which factors are more significant.

 Pareto Chart shows which part of the process is doing poorly and might contribute for
future and present failure and bottlenecks.