![]() ![]() Product changeovers were consuming up to two hours. Before the study period, process startup routinely took between 60 and 90 minutes to reach stable performance and produce product that met specifications. Historically, it has required excessive startup and changeover times to become stable enough for normal production. This study examines a high speed container making process that makes multiple products. Reducing Startup Time in Container Production The following example illustrates how SPC methods can be successfully used to reduce startup time. Each of the parameters in the OEE KPI (quality, uptime and throughput) is heavily impacted by startup and changeover time.Īn important approach to reducing startup time and the associated waste is to incorporate SPC methods to drive down variation and improve capability. Reduced OEE - Startup times have a strong negative impact on the Overall Equipment Effectiveness (OEE) rating of the production line.Non-productive cycles - If operators need to frequently stop and start the line, each episode reduces line availability and production throughput.Poor manpower and equipment utilization - Costs sunk into the make-ready cycle are not retrievable and are added to the total production costs.Reduced yields - While the operators are stabilizing the process it is not making usable product.Startup time increases production costs and overhead while not adding any value. Properly done, this approach improves productivity, reduces inventory and cuts lead time. If the manufacturer is in a JIT supply chain this is even more critical. ![]() Modern manufacturing strategy aims to make product to order. Startup Time – The Yield and Efficiency Thief
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