Lean Six Sigma Approach to Improve Overall Equipment Effectiveness Performance: A Case Study in the Indian Small Manufacturing Firm

Ramesh, C.; Manickam, C.; Prasanna, S. C.

doi:10.5958/2249-7315.2016.01349.6

Cited by 5 publications

(3 citation statements)

References 12 publications

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“…TBM focuses on improving equipment effectiveness, autonomous maintenance by operators, and small group activities 69 . Furthermore, Total Productive Maintenance (TPM) is an approach that aids in enhancing equipment availability and efficiency 70 .…”

Section: Comparison Criteriamentioning

confidence: 99%

Strategical selection of maintenance type under different conditions

Hamasha,

Bani-Irshid,

Al Mashaqbeh

et al. 2023

Sci Rep

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Selecting the appropriate maintenance type is a challenging task that involves multiple criteria working together. This decision has a significant impact on the organization and its overall market sustainability. The primary categorization of maintenance consists of two main types: corrective maintenance and preventive maintenance. All other classifications are encompassed within these two categories. For instance, preventive maintenance can be further classified as either predictive maintenance or periodic maintenance. Given the importance of this decision, this paper discusses the optimal maintenance type under different conditions. The scale of the business, the cost of machine failure, the effect of machine failure on the production schedule, the effect of machine failure on worker safety and the workplace environment, the availability of spare parts, the lifespan of the machine, and the manufacturing process are some of the factors that are covered in this paper. This paper primarily aims to present a comprehensive literature review concerning the strategic decision-making process for selecting the appropriate maintenance type under varying conditions. Additionally, the paper incorporates various models and visual aids within its content to facilitate and guide the decision-making procedure. Corrective maintenance is usually necessary in the case of small companies, significant impact on business or production plans due to failures, potential risks to public safety, ready availability of spare parts, and when production processes are not interdependent. If these parameters are not met, preventive maintenance can be a better option. Since these circumstances frequently do not occur simultaneously, it is imperative for the business to give them significant consideration.

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Section: Comparison Criteriamentioning

confidence: 99%

Strategical selection of maintenance type under different conditions

Hamasha,

Bani-Irshid,

Al Mashaqbeh

et al. 2023

Sci Rep

View full text Add to dashboard Cite

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“…In Industry 4.0, firm effectiveness of equipment plays a major role to lessen the number of rejections and achieve higher productivity [9]. In the current dynamic and challenging environment for SMEs, reliable manufacturing equipment and OEE are the main components for increasing performance and profitability of manufacturing systems [10].…”

Section: Overall Equipment Effectiveness (Oee)mentioning

confidence: 99%

An Empirical Investigation of the Relationship between Overall Equipment Efficiency (OEE) and Manufacturing Sustainability in Industry 4.0 with Time Study Approach

2018

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Nowadays, small and medium sized enterprises (SMEs) are becoming increasingly competitive. In order to fulfill the rapidly changing market and diversified demands of customers, the SMEs need to achieve and maintain high productivity and quality, with fast response, sufficient flexibility, and short lead times. Therefore, Industry 4.0 offers various manufacturing paradigms that might be a solution in order to increase the productivity of SMEs such as intelligent and flexible manufacturing. Furthermore, in the last decade, the emphasis on adopting eco-friendly practices, implementing sustainability measures, and protecting the environment has continued to grow, to gain traction across SMEs. In fact, because of this need, many SMEs are now adopting sustainable manufacturing practices in response to this increased focus on sustainability and environmental stewardship. The main purpose of this paper is to design and study the implementation of a sustainable, intelligent material handling system for material distribution with utilizing an agent-based algorithm as control architecture. A time study-based methodology has been implemented to evaluate the overall equipment effectiveness (OEE) to identify the matters that need to be resolved and optimized to increase the OEE percentage with consideration of the sustainability of the system. An exhaustive analytical trend applied to the generated time study data. Accordingly, further hardware, software, and layout design limitation and problems detected, and the proper solutions were anticipated. The observed time study results were presented, a fundamental set of analytical observation and information with associated histograms was reviewed. In addition, the study aims to recognize and analyze effective factors on the sustainability of improved processes, using a simple model. To do this, using experts’ viewpoints, affective factors on the sustainability of process improvement activities are determined.

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“…An increase in productivity and less rejections are the possible outcomes of increasing equipment effectiveness. The mentioned improvement is a major effect of the Industry 4.0 implementation on enterprises [18]. Considering the challenging market for SMEs, performance of the manufacturing system and reliable manufacturing equipment are currently considered the most important factors for increasing profitability [19].…”

Section: Introductionmentioning

confidence: 99%

A Hybrid Methodology for Validation of Optimization Solutions Effects on Manufacturing Sustainability with Time Study and Simulation Approach for SMEs

2019

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The properties of small- and medium-sized enterprises (SMEs) make them one of the most important categories of enterprises for the economics of challenging world. SMEs, in most countries, are still enterprises with marketing and financial challenges. In addition, most of these challenges are related to their production and product characteristics. On the other hand, SMEs should fulfil the costumer’s demands. In order to reach these goals, SMEs must reach the highest level of production quality and quantity and successfully sustain them. Consequently, various manufacturing paradigms have been offered by an Industry 4.0 concept, which offers a variety of solutions to increase the productivity and enhance the performance of SMEs. It should be noted that implementation of these manufacturing paradigms for SMEs is quite difficult and sometimes risky for several reasons. Still, amidst all these difficulties and challenges, the benefits and idealism of the Industry 4.0 paradigms prevail. From productivity to market, it is difficult to deny that SMEs are frightened by the challenges they face and fleeing from the potential of overcoming them. This paper is an extended version of the research by Ghafoorpoor Yazdi et al. (2018) and conducts a hybrid methodology to satisfy the SMEs by validating and verifying any optimization idea before implementing the Industry 4.0 concept. To reach the study goals, an intelligent Material Handling System (MHS) with agent-based control architecture has been developed. The developed MHS has been utilized for auto parts distribution. The system performance has been evaluated, and some solutions have been provided to optimize the performance of system. To evaluate the target system’s performance, an analytical time study method has been utilized. The time study has an Overall Equipment Effectiveness (OEE) standard approach to identifying the matters that need to be resolved and optimized to increase system performance. The other part of the methodology is generating a simulation model of the real system by use of ARENA® software to evaluate the system’s performance before implementing the optimization idea and modifying the real system. Furthermore, as the sustainability strategies create many synergistic effects for SMEs, after evaluating the effects of the optimization ideas on OEE percentage, the influence of the OEE changes on manufacturing sustainability has been investigated. The results show that optimizing the OEE in SMEs with sustainability approaches can create competitive advantages, rather than simply focusing on reducing unsustainability.

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Lean Six Sigma Approach to Improve Overall Equipment Effectiveness Performance: A Case Study in the Indian Small Manufacturing Firm

Cited by 5 publications

References 12 publications

Strategical selection of maintenance type under different conditions

Strategical selection of maintenance type under different conditions

An Empirical Investigation of the Relationship between Overall Equipment Efficiency (OEE) and Manufacturing Sustainability in Industry 4.0 with Time Study Approach

A Hybrid Methodology for Validation of Optimization Solutions Effects on Manufacturing Sustainability with Time Study and Simulation Approach for SMEs

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