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."

Cont.

KAIZEN

FIVE ‘S’

5 ‘S’ Seiri

(Sort)

Seiton

(Set in Order)

Seiso

(Shine)

Seiketsu

(Standardize)

Shitsuke

(Sustain)

Cont. 5S workflow

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

Thank

You !