A case study approach to productivity enhancement and calculation of Overall Equipment effectiveness

ABSTRACT Since the beginning of industrial era, the concept of productivity plays an important role in the development of the industry. The concept of the productivity arises from the production system. When the system is at growing stage, the emphasis is not on the efficiency of the system. Neither employer nor employees have the idea about the effectiveness and output is not in accordance with inputs that's why wastages are more and profits are less, but after the scientific management concepts people seems productivity conscious. The work is done in a medium scale industry to enhance productivity, calculate the overall equipment effectiveness and to analyze the current status of overall equipment effectiveness (OEE) on manufacturing cells and assesses current performance of the assembly line and identify the major opportunities for improvement in the short term. For that, the analysis is being done to identify where downtime is more and the causes responsible for productivity loss. When the analysis was done, there was lots of defects/downtime found in all three manufacturing cells under study. The main factor of setting downtime was found in calculation, which was responsible for the increase downtime. After defining problem we used Single minute of exchange (SMED) to reduce setting downtime. After implementation of SMED tools in assembly line we reduce setting downtime in Leak testing station. And this method was implemented all three cells with the help of SMED downtime reduced and productivity increased. Finally some suggestions were made to case company for improvement of OEE, productivity and lean manufacturing tools