industrial engineering topic: productivity (chapter 2)
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Tishk International University
Engineering Faculty
Mechatronics Department
Industrial Engineering
1st Grade- Spring Semester 2019-2020
TOPIC: Productivity
(Chapter 2)
Instructor: Sivakumar
Contents i. Productivity & Productivity Calculation
ii. Factors affecting the productivity
iii. Productivity Models and Index
iv. Productivity improvement programmes.
Introduction Productivity measures the level of efficiency and effectiveness with which resources are used to produce goods and services.
Highly productive firms are very profitable, pay better wages and constantly create new employment opportunities.
This course, “Productivity Measurement and Improvement Techniques” , is therefore designed to assist organizations in designing and implementing their own productivity measurement and improvement programs.
Productivity i. Definition of productivity
The ratio between the volume of output and corresponding volume
of labour input by production indices and the corresponding volume
of labour input as measured employment indices.
A measure of the efficiency of a person, factory, system etc. in
converting input useful output
ii. Calculation of productivity
Factors affecting the productivity
External
Factors
Internal
Factors
•rnal
• Taxation
• Govt. Law & Restriction concern
business
• Extent of national competition
• National resources and their mobility
• Availability of capital
• Technical issues and others.
• Plant location and layout
• Product design
• Technology, machinery and equipments
• Quality control.
• Material handling
• Managements techniques
• Work study and method study
Productivity Models
A productivity model is a measurement method
which is used in practice for measuring productivity.
A productivity model must be able to compute
Output / Input when there are many different outputs
and inputs.
SYSTEM INPUT OUTPUT
Transformation
Productivity Index
A productivity index is the ratio of productivity
measured in some time period to the productivity
measured in a base period.
For example, if the base period's productivity is calculated to be
period's productivity
1.5 and the following
is calculated to 1.90, the
resulting productivity index would be 1.90/1.50 =
1.267.
Productivity improvement
programmers.
• JIDOKA
• HEIJUKA
• KAIZEN
• FIVE ‘S’ • SMED
• JIT
• TPM
• POKA-YOKA
Productivity improvement programmers.
JIDOKA 1)
2)
3)
4)
Originally, this concept was first used in 1896 by Saichi Toyota.
Jidoka is also a Japanese term which means ‘Autonomation’. No it is not
simply ‘Automation’. It is ‘Autonomation’. Autonomation means ‘Automation with human touch’. Jidoka is one of the three pillars of the world famous ‘Toyota Production
system’ and also a key concept in ‘Lean Manufacturing’.
Cont.
Jidoka is “Automatic detection of problems or
defects at an early stage and proceed with the
production only after resolving the problem at its
root cause”.
HEIJUNKA
(Production Smoothing)
1) Heijunka (pronounced hi-JUNE-kuh) is a Japanese word
that means “leveling.”
2) When implemented correctly, Heijunka elegantly – and
without haste – helps organizations meet demand while
reducing while reducing wastes in production and
interpersonal processes.
3) Heijunka is Japanese term that refers to a system of
production smoothing designed to achieve a more even and
consistent flow of work.
Cont.
1) A related visual scheduling board known as a Heijunka box is often used in
achieving Heijunka style efficiencies.
2) The use of Heijunka as well as broader lean production techniques helped
Toyota massively reduce vehicle production times as well as inventory
levels during the 1980s.
Predictability
Stability Flexibility
KAIZEN 1) Kaizen is a Japanese term meaning "change for the
better" or "continuous improvement.“
2) Kai= Change, Zen= continuous improvement.
3) It is a Japanese business philosophy regarding the
processes that continuously improve operations and
involve all employees.
4) Kaizen sees improvement in productivity as a
gradual and methodical process.
5) Improvements generally follow the PDCA cycle
format, which stands for "plan-do-check- act."
FIVE ‘S’
5 ‘S’ Seiri
(Sort)
Seiton
(Set in Order)
Seiso
(Shine)
Seiketsu
(Standardize)
Shitsuke
(Sustain)
SMED SMED means Single-minute exchange of die.
The basic principles of SMED are:
1. Identify internal versus external changeover tasks.
2. Analyze each task’s real purpose and function.
3. Focus on no/low cost solutions.
4. Aim to eliminate changeover time.
SMED is typically broken down into three stages Stage 1 – Separate internal and external setup
Stage 2 – Convert internal setup to external setup
Stage 3 – Streamline internal and external elements
SMED
• Set Up Area
• Benchmark Timing
FIRST
• Analyze Areas • List
Unnecessary
Points
SECOND
• Separate External Elements
THIRD
• Identify Internal Element That Can Be Convert Into External
FOURTH
• Simplifies And Standardize Everything
FIFTH
Single-minute exchange of die
Steps in SMED
JIT 1) Just-in-time also known as JIT is an inventory management method
whereby labour, material and goods (to be used in manufacturing) are
in the
2)
re-filled or scheduled to arrive exactly when needed
manufacturing process.
`Just-in-time' is a management philosophy and not a technique.
JIT
Zero Inventory
Zero Lead Time
Zero Delay
Zero Failure
TPM 1) TPM (Total Productive Maintenance) is a holistic
approach to equipment maintenance that strives to
achieve perfect production:
No Breakdowns
No Small Stops or Slow Running
No Defects
POKA-YOKA
1) Poka-yoke is a Japanese term that means "mistake-
proofing" or "inadvertent error prevention".
2) A Poka-yoke is any mechanism in any process that helps an
equipment operator avoid (yokeru) mistakes (poka).
E.g :-
1) Car safety features
2) Treadmills
3) Microwaves
4) washing machines
5) dishwashers, and other household appliances
Cont.
Example of POKA-YOKA Car safety features:- Cars are equipped with many “error-proofing” features to keep us safe on the
road. Many cars will beep, or light up, if doors are open while the engine is
running, or if someone is in the passenger seat and their seatbelt is not fastened.
These are examples of warning functions, which alert users to potential errors.
Safety technology has advanced significantly in recent years.
Many cars nowadays come equipped with sensors that alert the drivers if they
are leaving their lane or warn them if they are too close to another car (or other
object).
Kanban 1) Its Japanese Technology and its derived as KAN= Card,
BAN= Signal
2) Kanban is a new technique for managing a software
development process in a highly efficient way.
3) Kanban underpins Toyota's "just-in-time" (JIT) production
system.
4) Although producing software is a creative activity and
therefore different to mass-producing cars, the underlying
mechanism for managing the production line can still be
applied.
5) The word Kanban is Japanese and roughly translated means
“card you can see.”
Cont.
Visualize the flow of work Limit
WIP (Work in Progress)
Manage Flow
Make Process Policies Explicit
Implement Feedback Loops
Improve Collaboratively, Evolve Experimentally (using the scientific
method)
6 Core Practices of the Kanban Method
1)
2)
3)
4)
5)
6)
Summary
• The following are discussed in the today lecture.
i. Productivity & Productivity Calculation
ii. Factors affecting the productivity
iii. Productivity Models and Index
iv. Productivity improvement programmes
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