IMPROVEMENT AND OPTIMIZATION OF OVERALL EQUIPMENT

EFFECTIVENESS OF A PRODUCTION LINE IN A SELECTED

APPAREL INDUSTRY

SUPERVISOR
Engr Mohammed Abdul Karim
Assistant Professor, Department of Industrial and Production Engineering .

NAME REGISTRATION NO.

Mohammed Shakaoat Hossain 2016334023

Noyon Kumar Da 2016334044

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I n t r o du ct i on

Ob j e ct i v es o f T h e S t u d y

L i t e r a t ur e R e v i e w

A n a l y si s A n d R e s ul t OUTLINE
L i mi t a t ion s o f T h e S t u d y

D i s c u s s i on

C o n cl u si on
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INTRODUCTION

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 OBJECTIVES OF THE STUDY
The main objective of this thesis is to use Simulation Approach to improve and use the Full Factorial Design to

optimize the O V E R A L L EQUIPMENT E F F E C T I V E N E S S . This thesis, therefore, focuses on:

1. To identify Six Big Losses of a production line and show the productivity of the production line through calculating Overall

Equipment Effectiveness (OEE).

2. Identifying major breakdown losses of the line.

3. Improvement of Production quantity by simulation

4. To investigate the effect of Availability, Quality rate, and Performance rate on Overall Equipment Effectiveness (OEE) through

Design of Experiment.

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❖ Readymade Garments(RMG)
Ready-made garments are mass-produced finished textile products of the clothing industry.

❖ Research Background
1 . Zuze and Fore investigated the existing OEE of a general electric company.
2 . Juliananda, M. et. al analyzed OEE of a pulp and paper industry to reduce six big losses of a pulp machine.

3 . Rubayet Karim and Chowdury M L Rahman performed a study on sewing section in a selected garments industry located
in Dhaka
4 . Masud, A.K.M. et. al studied sewing section of a RMG industry and performed PARETO analysis to identify significant losses
and conducted Why Why Because Logical Analysis (WWBLA) to minimize the losses

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 OVERALL EQUIPMENT EFFECTIVENESS
• There are some consistent metrics that have been around for improving and maintaining manufacturing
capability.
• Overall Equipment Effectiveness(OEE) is the gold standard for measuring manufacturing productivity.
• It’s a diagnostic tool.
• It was developed in the 1960’s by Seiichi Nakajima to support his “Total Productive Maintenance”
methodology.
• OEE uses three different values to calculate the efficiency of a process: Availability rate, Performance
rate, and Quality rate.

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 FACTORS OF OEE
Availability
• The availability is a comparison between the amount of time the machine is producing and the amount of time it was
scheduled to produce.

Performance Rate
• The performance rate can be defined as the ideal or design cycle time to produce the item multiplied by the output of the
equipment and then divided by actual cycle time. This will give the performance rate of the equipment.

Quality Rate
• The quality rate can be expressed as the production input into the process or equipment minus the
volume or number of quality defects then divided by the production input.

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 SIX BIG LOSSES
In Every Equipment Performance, Of Course, There Are Losses That Occur During Operation, This Is Described Into Six Big Losses On
Equipment By N a k a j i m a ( 1 9 8 8 ) , Including:
❖ Equipment Failure
❖ Setup And Adjustment Loss D o wn t ime L o s s

❖ Idling And Minor Stoppage

Speed Loss
❖ Reduced Speed

❖ Defects Is Process
Qu a l i t y L o s s
❖ Reduced Yield

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CALCULATION OF OEE

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LITERATURE REVIEW

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Overall Equipment Effectiveness
(OEE) of Ring Frame Section of a
Spinning Mill can be improved by
implementing a TPM tool named
KAIZEN.
Hosen, J. (2016)
Literature
Proper implementation of TPM can
reduce machine breakdown time and
improved repair & maintenance time
which in results improvement of
OEE
(Aziz, Karim, & Hossain,
2013)
Implementing TPM technique Why
Why Because Logical Analysis
(WWBLA) can significantly increase
OEE of a production line under
sewing section.
(Masud, Khaled, Islam,
Khan, & Jannat, 2007)
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Conducted 5 why analysis to identify
significant losses in a gas power
plant based on OEE value and
proposed some steps to overcome
those losses.
(Nusraningrum &
Senjaya, 2019)
Literature
Performed Response Surface Method Developed a simulation model before
(RSM) along with Design Expert and after robotization of a
software with Box-Behnken for manufacturing line focusing OEE
modeling and optimization of OEE factors to identify key areas of
taking availability, quality, and improvement.
performance rate as an input parameter
and quadratic and the cubic model was
recommended as optimize model.
(Kampa, Gołda, &
(Chikwendu, Chima, &
Paprocka, 2017).
Edith, 2020)
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METHODOLOGY

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 STEPS IN CONDUCTING THE STUDY
1 Idea generation

2 Formulating Objectives of The Research by Studying Previously Published Article

3 Studying and Investigating the System Through Reviewing Literature

4 Choose Industry and Data Collection Methodology

STEPS 5 Identify Most Significant Losses Through Pareto Analysis

6 Finding causes behind the most Significant Losses Through Ishikawa Diagram

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Modeling the Production Line Through SIMUL8

8 Improvement of production through simulation

9 Optimization of OEE Through DOE.

10 Presenting Results and Discussion

ANALYSIS AND RESULT

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 AVAILABILITY CALCULATION

T A B L E : 1 Availability Calculation Table

Setup and Adjustment Planned Operating Time Actual Operating Time

Day Breakdown Loss (Minutes) Availability
Loss (Minutes) (Minutes) (Minutes)

1 62 42 630 526 83.49%

2 57 60 630 513 81.5%

3 64 82 630 484 76.8%

4 52 70 630 508 80.63%

5 97 25 630 508 80.63%

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 PERFORMANCE RATE CALCULATION

T A B L E : 2 Performance Rate Calculation Table

Theoretical Cycle Time Actual Operating Time

Day Total Workers Actual Production Performance Rate
(Minutes) (Minutes

1 15.98 526 632 71.11 %

2 15.98 513 27 628 72.45%

3 15.98 484 592 72.39%

4 15.98 508 602 70.14 %

5 15.98 508 639 74.45%

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 QUALITY RATE CALCULATION

T A B L E : 3 Quality Rate Calculation Table

Day Number Produced Defective Count Good Count Quality Rate

1 632 19 613 96.99 %

2 628 23 605 96.34 %

3 592 25 567 95.78 %

4 602 24 578 96.01 %

5 639 18 621 97.18%

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 OVERALL EQUIPMENT EFFECTIVENESS(OEE) CALCULATION

OEE= AVAILABILITY × PERFORMANCE RATE × QUALITY RATE

T A B L E : 4 OEE Calculation Table

Day Availability Performance Rate Quality Rate OEE Average OEE

1 83.49% 71.11% 96.99% 57.58%

2 81.5% 72.45% 96.34% 56.89%

3 76.8% 72.39% 95.78% 53.25% 55.786%

4 80.63% 70.14% 96.01% 54.29%

5 80.63% 74.45% 97.18% 58.33%

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 PARETO ANALYSIS
❖C o n d u c t e d T o I d e n t i f y M o s t S i g n i f i c a n t L o s s e s

180 120.00
157
160
100.00 100.00
140 93.39
86.21
120 78.45 80.00

100 65.52 Vital Few

60.00
80 71

60 40.00
45
40
27 25 23 20.00
20

0 0.00
Needle Breaks Looper Thread Breaks Bobbin Thread Breaks Hook Damage Needle Thread Breaks Pressure Feed Damage
Breakdown Name
Breakdown Duration

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 FISHBONE ANALYSIS (NEEDLE BREAKS)

CAUSE EFFECT

Equipment Policy People

Sewing over pins

Thread catches on the spool
Sewing over a zipper
Thread wraps around the spool cap Not changing needle on Not using the correct needle
daily basis
Sewing machine needle too small Fabric is pulled through the
machine

Needle
Breaks
The needle is bent Improper needle or looper adjustment
Needle not all the way inserted Needle hits the
The needle is bad to start with
The needle screw is not tight enough bobbin case
Needle strikes on the
Hard Sewing Garments Friction with throat plate hook

Materials Procedure

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 FISHBONE ANALYSIS (LOOPER THREAD BREAKS)

CAUSE EFFECT

E q u i pt m e n t M e a s u rt e m e n t P e o tp l e
Threading the needle before
threading the looper

Thread tangled Not following proper

Inaccurate tension in thread
operation manual
Placing the thread on
the wrong side of the
looper
Looper
Thread
Break
Thread quality is poor
Disintegration of thread Needle is bent or broken
over time
Inappropriate oiling

M a t etr i a l s E n v i r o tn m e n t P r o c te d u r e

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 FISHBONE ANALYSIS (BOBBIN THREAD BREAKS)
CAUSE EFFECT
Equipment Measurement People

Thread tension is too tight Bobbin is inserted backward

Hook timing is off
Bobbin is not wound correctly
Thread is snagging on a burr Sewing machine is not threaded correctly
on a bobbin case Using the wrong bobbin

BOBBIN THREAD
BREAK

Thread quality is poor Bobbin is warped or damaged Bobbin case is full of lint

Materials Environment Procedure

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 SIMULATION STUDY AND ANALYSIS

ASSUMPTIONS
➢ The performance losses are captured within the cycle time
➢ The queue capacity was set to infinite
➢ The quality losses are neglected
➢ The processing time of each activity is fixed and defined.

PROPOSED MODEL OF THE SIMULATION

➢ Additional resource was increased by increasing workstation as well as increasing manpower in the line.

➢ Eliminating Needle Breaks, Looper Thread Breaks of the existing production line

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 Existing Production Line

Figure : 1 Simulation Model Of The Existing Production Line

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 Queue Report Existing production line

Figure : 2 Queue Report of The Simulation Model Of The Existing Production Line
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 PROPOSED SIMULATION MODEL

Figure : 3 Proposed Simulation Model Of The Existing Production Line

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QUEUE REPORT OF THE PROPOSED MODEL

❑ From the queue result of the

proposed model, it is seen that
average queue size of the activity
3, 4, 6, 10 is improved.

Figure : 4 Queue Report of The proposed Simulation Model

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 Comparison of Improvement

T A B L E : 5 Comparison of Improvement in Queue Sizes.

Operation No. Average Queue Size in Average Queue Size in

The Existing Model The Proposed Model

3 4235 1097

4 1563 1097

5 86 1741

6 502 1

10 761 812

T A B L E : 6 Comparison of Improvement in Output

Model Output Percentage improved

Existing 3397
8.87%
Proposed Model 3728

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 OPTIMIZATION OF OEE THROUGH DOE

Full Factorial Design

Design Summary

Factors: 3 Base Design: 3, 8

Runs: 8 Replicates: 1

Blocks: 1 Center pts (total): 0

T A B L E : 7 Experimental Setup In Minitab18

Availability Performance Rate Quality Rate OEE
0.75 0.67 0.95 0.477375

0.8 0.67 0.95 0.5092

0.75 0.67 0.97 0.487425

0.8 0.67 0.97 0.51992

0.75 0.72 0.95 0.513

0.8 0.72 0.95 0.5472

0.75 0.72 0.97 0.5238

0.8 0.72 0.97 0.55872

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 ANOVA TABLE

T A B L E : 8 ANOVA Table

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 0.005226 0.001742 2035.98 0.000

Quality Rate 1 0.000232 0.000232 271.28 0.000

Performance Rate 1 0.002768 0.002768 3235.03 0.000

Availability 1 0.002226 0.002226 2601.62 0.000

Error 4 0.000003 0.000001

Total 7 0.005229

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 R e g r e s s i on A n a l y s i s : O E E v s A , P R , Q R

Regression Equation
OEE = -1.0342 + 0.5386 Quality Rate + 0.7440 Performance Rate + 0.6672 Availability

T A B L E : 9 Variables and Its Significance Value

Te r m Coef SE Coef T-Value P-Value

Constant -1.0342 0.0342 -30.22 0.000

Quality Rate 0.5386 0.0327 16.47 0.000

Performance 0.7440 0.0131 56.88 0.000

Rate
Availability 0.6672 0.0131 51.01 0.000

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 C o n t ou r P l o t a n d S u r f a c e P l o t

FIGURE: 5 Contour Plot of OEE Vs PR, QR FIGURE : 6 Surface Plot of OEE Vs PR, QR

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LIMITATIONS AND RECOMMENDATIONS

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 LIMITATIONS

T h e f o ll owi n g a r e t h e l i mi t a t ion s o f t h i s s t ud y :
➢ Real time data collection was not possible, third-party data were used. Real time data collection would give more realistic result.
➢ There are many other lean tools rather than OEE which can be implemented in RMG such as 5S, Kaizen, Error proofing, Kanban etc. This study does not discuss their
significance.
➢ For identifying causes behind significant losses, Fishbone analysis is conducted, but more precise root cause can be found by Why Why Because Logical Analysis
(WWBLA) or 5 why analysis.
➢ The results of OEE and simulation modeling would have been more accurate if data could be collected for longer period and quality factor related data could be integrated
during modeling.
➢ Worker performance will be different each day, but the simulation assumes that the processing time of the station is consistent for every product.
➢ Cost of increased resources in the proposed model were not considered into account.

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 RECOMMENDATIONS

Recommendation for Future Work

➢ The study depicts the idea of improvement in production as well as OEE by simulation, In sewing section. Further study can be performed on other

section of the industry such as cutting section, finishing section, sample section.

➢ Quantifying the investment value for changes to the current scenario based on manufacturing cost and payback time.

➢ Analyzing each station of a production line separately using the OEE approach to identify which kind of waste is the most recurrent for a specific set of

activities; then, use simulation to check scenarios of improving production.

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 D I S CUS SI ON

➢ Average OEE for studied production line was 55.786% (Table 4.6) which is less than global standard value 85%.
➢ It is seen from calculation table at day three OEE value is 53.25% which is less than other four days and Availability,
Performance Rate and Quality Rate were 76.8%, 72.39% and 95.78%.
➢ From the Pareto Analysis it is evident that, Needle breaks, Looper thread Breaks, and Bobbin Thread Breaks comprises
the major breakdown that stops the production.
➢ From the output of the simulation, it is seen that total completed job is 3397 units and from the performance rate
calculation table, it is seen that total completed job is 3093 units, which indicates that simulation result is almost 91%
accurate.
➢ Form the output of proposed simulation model (Table 4.14), it is seen that total completed job is 3728 units that means
output of the existing model can be improved 8.87% by applying the proposed model.
➢ Focusing day three OEE value the optimal value was sorted out through Design of Experiments modeling approach and
those value were Availability 80%, Performance Rate 72% and Quality Rate 97% and finally optimal OEE 55.872%.

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 C ON C LUS I ON

➢ A production line under sewing sections from HopLun Bangladesh Ltd was selected for detailed study.
➢ Based on five days data given by their IE department necessary analysis were done and average OEE was 55.786%, which is less
than world class standard.
➢ Pareto Analysis and Fish Bone Analysis were conducted to sort out most significant causes and it was found that Needle breaks,
Looper thread Breaks, and Bobbin Thread Breaks comprises the major breakdown that stops the production.
➢ Simulation model of existing scenario and a proposed model were developed through which output can be increased by 8.87%.
➢ For optimization purpose two level three factors Design of Experiment was performed using Minitab 18 and optimal values were
found as Availability 80%, Performance Rate 72% and Quality Rate 97% .

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Thank You
For Your Attention

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