2. Overall Efficiency From the 24/7 available time, we foresee 4 hours per week

Question

2. Overall Efficiency From the 24/7 available time, we foresee 4 hours per week for preventive maintenance. During the production of one week, we foresee 10 changeovers with an average time of 30 minutes, there is once a week a breakdown of the electricity which stops the production for hour and we have on average 30 minutes every day that the production has to be stopped for unplanned repairs. Equipment has on average 1 hour losses due to idling, slow down and reduced production speed due to product issues Our quality losses are about 3% of all items produced, so of the net operating time. Calculate: The total operation efficiency and the intermediate efficiencies We have a production process which has four steps with different production capacity and all steps should operate with max capacity 3. Step 1 = 150 unitshour Step 2 120 units/hour Step 3 # 120 units /hour Step 4 = 50 units hour Our total production 24/7 ver 220 days is 375 million Euro Draw this situation and comment. What do you see? Is there a special point? How much goods are going in and what is coming out? Step 2 breaks down for 1 hour, what is the effect on the production? Step 4 breaks down, what is the effect on the production?

Explanation / Answer

2) Calculation of Overall Efficiency:

Consider the following notation:

Solution:

As it is given as 24/7 production time, total production time per week in hours = 24*7 = 168 hours/week

Now, let us add the Non-production hours:
(i) Loss due to changeover time = No. of changeovers * changeover time = 10 * 30 = 300 Mins/week = 5 hrs/week
(ii) Loss due to Breakdown of power = 60 mins/week = 1 hour/week
(iii) Loss due to unplanned repairs = 30 mins/day = 30*7 = 210 mins/week = 3.5 hours/week
(iv) Loss due to Equipment idle due to product issues = 1 hour/day = 1*7 = 7 hours/week
(v) Loss due to quality issues which results in loss of net operating time = 3%

Total Operating efficiency = Total Production hours per week - sum of all losses (i to v)/Total Production hours per week * 100%
= {168 - (5+1+3.5+7+(168*3%))}/168 * 100%
= {168 - (5+1+3.5+7+5.04)}/168 * 100%
= {168 - 21.54}/168 * 100%
= 146.46/168 * 100%
= 87.18%

Hence, the Total Operating Efficiency = 87.18%

Intermediate Efficiencies:

(i) Due to changeover time = (168-5)/168 = 96.43%
(ii) Due to breakdown of power = (168-1)/168 = 99.40%
(iii) Due to unplanned repairs = (168-3.5)/168 = 97.92%
(iv) Due to Equipments being idle = (168-7)/168 = 95.83%
(v) Due to quality issues = 97%

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