Productivity improvement by lost time reduction

Abstract

The objective of this thesis is to improve productivity by reduction of lost time for machining line. Lost time in production can be categorized into 4 types. There are planned down time, down time losses, line balancing losses and scrap losses. From a problem analysis of a sample factory, it has been found that the major lost time in machining line composes of line balancing losses and down time losses. Reducing non-cutting time and using efficient cutting condition resulted in the improvement of line balancing losses. Down time losses was reduced by the reduction of inspection time, adjustment time and tool change time. Productivity and percentage of lost time has been used to evaluate the effectiveness of improvement. Result between before and after improvement has been concluded that the productivity has been increased from 9.4 pieces/ man-hour to 10.7 pieces/man-hour or improvement of 14%, Line balancing losses has been reduced from 1.07 minutes/pieces to 0.72 minutes/ pieces. Down time has been reduced from 17.41 % of operation time to 10.69 % of operation time.