Automated line is widely applied in industry especially for mass production with less variety product. Productivity is one of the important criteria in automated line as well as industry which directly present the outputs and profits. Forecast of productivity in industry accurately in order to achieve the customer demand and the forecast result is calculated by using mathematical model. Mathematical model of productivity with availability for automated line has been introduced to express the productivity in terms of single level of reliability for stations and mechanisms. Since this mathematical model of productivity with availability cannot achieve close enough productivity compared to actual one due to lack of parameters consideration, the enhancement of mathematical model is required to consider and add the loss parameters that is not considered in current model. This paper presents the investigation parameters of productivity losses investigated by using DMAIC (Define, Measure, Analyze, Improve, and Control) concept and PACE Prioritization Matrix (Priority, Action, Consider, and Eliminate). The investigated parameters are important for further improvement of mathematical model of productivity with availability to develop robust mathematical model of productivity in automated line.

The basic attributes of any industrial machines and systems are productivity rate and quality of products. Attributes of productivity are related to the theory of reliability let alone the theory of efficiency of machines. Publications in area of productivity of the industrial systems enable to write the productivity theory for the industrial machines and systems. This theory shows the links between productivity, reliability, technological and technical parameters and the structure of machines with complex designs. Automated production lines are considered industrial systems for the collection of serial and parallel stations arranged according to a certain structure that depends on a technological process of machining parts. Manufacturers require correct and clear mathematical models to calculate the productivity of the automated lines with high accuracy. The mathematical models for productivity rate of industrial systems with complex design define their structures according to the level of output. This paper presents an analytical approach to the productivity rate of automated lines with stations and mechanisms that display different failure rates and processing times. The typical designs of industrial automated lines are considered by three types of structure: multi-station ’s automated line of serial, parallel action and serial-parallel action. All designs can be presented using linear, circular and rotary arrangements. The analytical equations allow for the output of the automated lines to be modeled with different failure rates for the stations and mechanisms yielding results close to the actual productivity values.

Productivity rate (Q) or production rate is one of the important indicator criteria for industrial engineer to improve the system and finish good output in production or assembly line. Mathematical and statistical analysis method is required to be applied for productivity rate in industry visual overviews of the failure factors and further improvement within the production line especially for automated flow line since it is complicated. Mathematical model of productivity rate in linear arrangement serial structure automated flow line with different failure rate and bottleneck machining time parameters becomes the basic model for this productivity analysis. This paper presents the engineering mathematical analysis method which is applied in an automotive company which possesses automated flow assembly line in final assembly line to produce motorcycle in Malaysia. DCAS engineering and mathematical analysis method that consists of four stages known as data collection, calculation and comparison, analysis, and sustainable improvement is used to analyze productivity in automated flow assembly line based on particular mathematical model. Variety of failure rate that causes loss of productivity and bottleneck machining time is shown specifically in mathematic figure and presents the sustainable solution for productivity improvement for this final assembly automated flow line.