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1

Performance evaluation to measure production equipment effectiveness in block cutting machine (gang saw)

Karaabat Varol Merve

Mining Science

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2023

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Vol. 30

157--169

EN

The demand for natural stone is increasing with the construction development in Turkey. In natural stone quarries, frame saws and circular saw machines are preferred for block production. Frame saw machine is also known as gang saw and it is the most commonly used for slab production in stone cutting factories. Therefore, gang saw machine selection is the most significant factor in the number of slabs, size of slabs, production time, and cost. Also, cutting machine performance is important because it can increase productivity and quality while reducing costs. Overall Equipment Effectiveness (OEE) is a crucial technique for measurement of the performance, availability, and quality of the machine. Production Equipment Effectiveness (PEE) is a method of losses owing to downtime, reduced speed, and quality. However, there is no study in the literature on how to use effectiveness for stone cutting machines such as gang saw machines, circular saw machines, bridge plate cutting machines, bridge plate polishing machines, etc. In this study, 3 gang saw machines have been carried out by evaluating both OEE and PEE. It determines the time losses. The estimation of OEE and PEE of gang saw machines have been presented via 23 blocks for every machine. As a result, OEE values have been calculated as 80% and PEE values have been calculated as 90%. This situation shows that this factory uses the equipment effectively and slabs are quality for sale.

2

Case Study: Testing the Overall Efficiency of Equipment in the Production Process in TX Plant Simulation Software

Pekarčíková Miriam, Trebuna Peter, Kliment Marek, Trojan Jozef, Kopec Ján, Dic Michal, Kronová Jana

Management and Production Engineering Review

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2023

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Vol. 14, No. 1

34--42

EN

The article deals with a widely used method of measuring the overall efficiency of equipment (OEE), which in combination with technologies and software tools is gaining in importance. The overall efficiency of OEE equipment is a key performance metric for machines and equipment to identify hidden capacities and increase production productivity. The intensification of Industry 4.0 in traditional manufacturing companies supports and creates the conditions for their transformation into a smart factory. The integration of intelligent machines and devices with complex human-machine communication network systems requires a new direction in measuring and increasing OEE. Mass customization, resp. personalization of production raises a high need to monitor, improve and further maintain productivity. The aim of the article is to create a simulation model of the production process and test the energy consumption of selected equipment using TX Plant Simulation software with a proposal of measures to increase the OEE of the company.

3

Geometric approach to machine exploitation efficiency : modelling and assessment

Loska Andrzej, Paszkowski Waldemar

Eksploatacja i Niezawodność

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2022

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Vol. 24, no. 1

114--122

EN

This article presents a new approach to the exploitation assessment of machines and devices. A key aspect of this approach is the construction of the assessment model based on the geometric representation of measures associated with each other, which covers the full specifics of the exploitation process. This approach is successfully implemented by the Overall Equipment Effectiveness (OEE) model, which is fully susceptible to the geometric modelling process due to the three-way system of assessed exploitation aspects. The result of this approach is the vectored OEE model and its interpretation in terms of time series of changes in values of components. Methods of determining vector calculus measures were developed, including the second-order tensor and gradient. This is the subject of the variability of the reliability conditions of machines or production processes. It allows for the realisation of an exploitation assessment based on dynamic changes in the values of their components in the time domain. This is a significant difference to the classical static approach to such an assessment. The developed new geometric OEE model was confirmed by verification tests using the LabView software, based on two parallel data sets obtained with analytical and simulation methods using the FlexSim software.

4

Assessment of the modernized production system through selected TPM method indicators

Michlowicz Edward

Eksploatacja i Niezawodność

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2022

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Vol. 24, no. 4

677--686

EN

The subject of the studies is the evaluation of the operation of a production system after modernization. The analysed case concerns the modernization forced by the end of the product lifetime. The proposed methodology is that of a multicriterial evaluation of the system operation after modernization. The evaluation criteria are selected TPM indices: availability of machinery and equipment, production process capacity, product quality and overall equipment effectiveness (OEE). The additional criteria are reliability indices MTBF and MTTR of studied production lines and the MTTR of the most unreliable equipment in each analysed line. A yearly monitoring of production process was proposed for obtaining the statistical credibility of the evaluation results. Additionally, a fuzzy indicator of acceptability of the modernization assessment was proposed. The paper presents the results of studies of the system for production of zinc concentrate from post-production waste. The obtained values of OEE, MTBF and MTTR indicators for the three tested lines make it possible to state that the modernization carried out is acceptable.

5

Influence of temperature based process parameter compensation on process efficiency and productivity

Pater Jerzy, Basara Damian, Stadnicka Dorota

Technologia i Automatyzacja Montażu

|

2021

|

nr 2

44--51

PL

Warunki w środowisku pracy związane np. zapyleniem, wibracjami lub temperaturą mogą mieć negatywny wpływ zarówno na proces produkcyjny, jak i na wytwarzany produkt. Nieodpowiednie i niestabilne warunki mogą powodować niestabilność procesu produkcyjnego i pogarszać jakość wytwarzanych wyrobów. Co więcej, może to spowodować stratę czasu i zmniejszyć wydajność i produktywność. W artykule przeanalizowano problem wpływu temperatury na proces produkcyjny. Monitorowanie temperatury nie wystarczy, aby zapewnić osiągnięcie celów produkcyjnych. Konieczne jest odpowiednie dostosowanie parametrów procesu produkcyjnego, aby nie powstawały niezgodności wynikające ze zmian wartości temperatury i aby nie pojawiały się opóźnienia. Artykuł dotyczy wydajności i produktywności systemu produkcyjnego, który pracuje w niestabilnym środowisku pracy. Autorzy udowadniają, że zastosowanie kompensacji parametrów procesu produkcyjnego może znacząco poprawić zarówno wydajność, jak i produktywność. Wartości wydajności i produktywności były monitorowane w ustalonym okresie czasu dla systemu produkcyjnego, na którym realizowany jest proces produkcyjny. Następnie wprowadzono procedurę kompensacji parametrów procesu. Po czym, w określonym przedziale czasu zebrano dane i porównano wartości wydajności i produktywności z wartościami uzyskanymi wcześniej. Dodatkowo autorzy proponują wprowadzenie wskaźnika całkowitej efektywności wyposażenia (OEE) i w artykule przedstawiono informacje o sposobach zbierania danych dla obliczenia OEE.

EN

Conditions in the working environment related e.g. to dust, vibration or temperature may have a negative impact on both, the production process and the manufactured product. Inappropriate and unstable conditions can cause instability of the production process and deteriorate the quality of manufactured products. Moreover, this can induce time waste and decrease the efficiency and productivity. In this paper the problem of temperature influence on a manufacturing process is analyzed. Monitoring of the temperature is not enough to ensure the achievement of manufacturing goals. It is necessary to adapt the parameters of the production process accordingly so that no nonconformities arise due to changes in temperature values and no delays appear. This paper deals with the efficiency and productivity of a manufacturing system which work under unstable working environment. The authors prove that application of the manufacturing process parameters compensation can significantly improve both, efficiency and productivity. The values of efficiency and productivity were monitored within a fixed period of time for a manufacturing system, on where the manufacturing process is realized. Then, a procedure of process parameters compensation was introduced. Next, within a fixed period of time the data were collected and the efficiency and productivity values were compared with the values obtained before. Additionally, the authors propose to introduce the Overall Equipment Effectiveness (OEE) indicator and present information about ways of data collecting.

6

Knowledge and information management

Kuryło Piotr, Wysoczański Adam, Bonarski Piotr

System Safety : Human - Technical Facility - Environment

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2021

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Vol. 3, nr 1

1-10

EN

The paper describes selected issues related to knowledge management in a manufacturing company with a detailed analysis of the impact of optimal management using the MES system on financial and production results. The study presents an analysis of the company’s results before and after the implementation of the knowledge and information management system in a manufacturing company. Moreover, the paper presents an analysis of the company’s operations and defines a strategy for further activities aimed at increasing the financial and operational efficiency of the analysed production company.

7

Availability Study of a Longwall Shearer Including Phases of its Operation

Brodny Jarosław, Brzana Estera

Multidisciplinary Aspects of Production Engineering

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2021

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Vol. 4, Iss. 1

200--211

EN

The mining production process includes a number of sub-processes, the most important of which is mining the rock mass. In this process, increasingly modern mining machines are being used to replace human labor and to achieve high productivity. Full utilization of the potential of these machines is of great importance for the efficiency of individual stages and the whole process of mining production. In the process of mining the rock mass, the use of machinery of a mechanized longwall system is of fundamental significance. Their availability, efficiency and reliability significantly affect the efficiency of the whole mining production process. The paper refers to the availability of a longwall shearer as the basic machine of a mechanized mining system. Based on the analysis of diagnostic signals, recorded by the industrial automation system, the availability of the longwall shearer was determined for 10 selected cycles of its operation. The analysis also included the phases of these cycles, treated as separate periods of the shearer’s work. This division is a consequence of a great difference in the character of the shearer’s work in particular phases of the operating cycle. The analysis covered the phases of cutting, mining and shunting. The determined temporal waveforms and the shearer’s availability in these phases show their great diversity. Therefore, the results indicated the necessity to analyze the operation of mining machines in their characteristic periods, which can be the basis for minimizing unplanned interruptions in their operation and improving the efficiency of their use.

8

Improvement of the production process with the use of selected KPIs

Czerwińska Karolina, Pacana Andrzej, Dwornicka Renata

System Safety : Human - Technical Facility - Environment

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2020

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Vol. 2, nr 1

307--315

EN

Faced with ever-increasing customer demands and global competition, companies are forced to look for production reserves, increase efficiency and productivity. Hence, the need to monitor the use of the machine park has arisen, making it possible to identify waste and production reserves in the implemented technological processes. The aim of the article is to evaluate the effectiveness of the production line of internal frame doors and to analyze the correctness of the use of selected key indicators of the production process effectiveness. This article proposes a response to the problems formulated in manufacturing companies, including practical aspects of the use of specific measures to assess the effectiveness of the use of technical infrastructure. The solutions presented in the article can be used in practice for improvements in production units.

9

Managing the effectiveness of machines during the assignment of tasks to the production

Krynke Marek

Quality Production Improvement - QPI

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2020

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Vol. 2, Iss. 1

188--196

EN

The allocation of production tasks to specific production resources is an important part of preparing the manufacturing process. The amount of profit and costs incurred depends on this division. The efficiency of production resources depends not only on the technologies used, but also on the tasks that will be carried out on them. Therefore, the management of machine efficiency includes both an evaluation (analytical and assessment undertaking, e.g. OEE) and planning activities aimed at maximizing the efficiency of machines by appropriately assigning production tasks to them. The article presents the problem of the allocation of production of various products to various production resources, including the efficiency of the use of machines and devices, emphasizing the possibilities of undertaking optimization actions in the cost management process. A mathematical model was formulated for this issue. An algorithm solving the problem of allocation of production tasks is presented. The solution was obtained using the Octave computing environment.

10

Potential and Limits of OEE in the Total Productivity Management

Šajdlerová Ivana, Schindlerová Vladimíra, Kratochvíl Jiří

Advances in Science and Technology. Research Journal

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2020

|

Vol. 14, no 2

19--26

EN

For years, management of companies has been turning to proven techniques and tools to achieve even higher productivity. They hope for, if possible, all-inclusive, easy and efficient procedures to manage their production systems. In principle, this applies to all organizations, regardless of the sector or the company focus. Especially in industrial enterprises with different machines and equipment for production processes, the quantitative indicator „Overall Equipment Effectiveness“ (OEE) has been used in recent years as a key indicator to monitor their efficiency and process performance. This indicator provides relatively simple information about the possibilities and utilization of machines and equipment as well as the quality achieved in the production processes. If the OEE indicator is determined correctly, based on the available and correct data in a system, processes can be better controlled, managed and improved. However, it is important to properly monitor (decode) the data and to understand them. The paper presents the potential but also the limits (obstacles) of Overall Equipment Effectiveness (OEE) on case studies in selected domestic enterprises in the Moravian-Silesian region.

11

Analysis of the efficiency of machine use on the production line of interior doors

Czerwińska Karolina, Pacana Andrzej

Zarządzanie Przedsiębiorstwem

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2019

|

Vol. 22, nr 2

2--6

EN

The first part of this article presents methodological assumptions for the construction of the overall equipment effectiveness index (oee). Further, the shortened technological process of the product is presented and the analysis of losses in the context of the causes of machine downtime and the type of non-conformity of the products is made. The last part presents the results of the diagnosis in the scope of monitoring and analysis of the total efficiency index of equipment (oee) carried out on an exemplary production line of doors and proposes comprehensive improvement actions in order to improve the unsatisfactory condition of the machinery stock use efficiency.

12

Klucz do jakości cementu

Kawalec Paweł

Surowce i Maszyny Budowlane

|

2019

|

nr 1

80--85

PL

Ile kosztuje waszą cementownię produkcja klinkieru niespełniającego wymagań jakościowych? Ile można zaoszczędzić poprawiając OEE o parę procent, zwiększając produkcję czy dodając parę procent mniej klinkieru czy cementu? I jaki wpływ na stabilnośc jakościową wkładu piecowego mają suroce mineralne?

13

Study of the Vision System’s Impact on Increasing the Reliability of the Production System

Franek Jakub, Nalepa Bartłomiej

New Trends in Production Engineering

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2019

|

Vol. 2, Iss. 2

46-56

EN

The purpose of the paper is to present the validity of the investment of a production plant in the development of production automation. The optimal use of production lines is the way to achieve the right return on investment and profits. Any unplanned stops reduce profitability of production and do not allow to achieve high production output. The introduction of various types of safety devices and process automation allows to prevent unwanted events. In particular, relieving employees of their responsibility and thus avoiding breakdowns caused by operator error can lead to an effective increase in Overall Equipment Effectiveness (OEE).The publication presents a study of the impact of the use of a vision system on increasing the reliability of the production system. As a result, an effective vision system based on a 3D sensor has been developed, which protects the production line against collision of the robot's chuck plate with final products, thus not leading to the collision and destruction of the robot's tools. The camera has been implemented in the robot's control system, which excludes the need to change the settings, because the necessary change of work parameters is made automatically via the communication interface, thus making the work easier for employees when retooling the production machine between orders. Increasing the Overall Equipment Effectiveness and high level of Return Of Investment (ROI) allow for an unequivocal decision on the importance of the investment decision. The financial expense allowed for increasing the efficiency and productivity of production line, which contributes to the growth of the company's competitiveness. The predictability of lead time has been significantly improved, which led to an increase in customer satisfaction.

14

Performance evaluation of continuous miner based underground mine operation system: An OEE based approach

Banerjee Sumit

New Trends in Production Engineering

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2019

|

Vol. 2, Iss. 1

596--603

EN

CM is a globally renowned machine, designed to work as a mass production technology for underground coal. Different major coal producers across the globe are using this technology for decades to produce underground coal efficiently. India is also one of the major players globally in the arena of coal production and adopted this cutting edge technology since last decade by implementing at. few of the selective underground coal mining projects. Performance of CM technology is influenced by the geo-mining condition, fleets of other ancillary units and reliability of subsystems while implementation of this system depends largely on the extent of reserve. These aspects generate a scope of large scale research and development in this field. Overall Equipment Effectiveness (OEE) is the parameter to benchmark the equipment performance globally. OEE is the product of equipment availability, performance and product quality. This mining machine based paper focuses on the Overall Equipment Effectiveness (OEE) of the complete CM based operation to identify the vulnerable systems, which helps to design proper preventive maintenance programme. The CM based system is divided into few subsystems, such as; electrical, cutter, gathering arrangement, traction, hydraulic, chassis, feeder breaker, shuttle car, CM conveyor and out-bye conveyor. The downtime data used for this analysis is collected from an underground coal mine situated in the central part of India, belongs to one leading coal producing company of the country. From analysis it was found that, electrical systems and conveyors are among most vulnerable systems and deserves more care during maintenance. On the basis of these results recommendations are made to redesign the Preventive Maintenance Programme, in order to avoid the lower availability as well as lower OEE.

15

Exploitation Policy in the Aspect of Industry 4.0 Concept – Overview of Selected Research

Timofiejczuk A., Brodny J., Loska A.

Multidisciplinary Aspects of Production Engineering

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2018

|

Vol. 1, Iss. 1

353--359

EN

The article is a review of completed research on developed and implemented innovative and technologically advanced technical systems. According to the Industry 4.0 concept they can have a significant impact on the efficiency of production processes and product development. In this perspective, the key aspect seems to be maintenance management of technical systems, realized both in the operate phase as well as during service and repair works. There were discussed research results of authors and developed application solutions supporting decision-making processes, in terms of three main periods of realization of exploitation processes: short, medium and long-term.

16

Analysis of the correctness of determination of the effectiveness of maintenance service actions

Daniewski K., Kosicka E., Mazurkiewicz D.

Management and Production Engineering Review

|

2018

|

Vol. 9, No. 2

20--25

EN

This paper reports the results of an analysis of indicators describing the effectiveness of actions taken and repairs made by the maintenance services in a food industry company which had implemented a new manufacturing execution system (MES) 10 months prior to the study. The application of the above effectiveness indicators plays a significant role in the rationalization of functioning of maintenance services. Therefore, it is vital that they are calculated correctly and interpreted in a way that has a positive effect on the organization of maintenance works. The paper investigates four effectiveness indicators employed by the maintenance services of the company in question, i.e., mean time to failure (MTTF), mean time between failures (MTBF), mean time to repair (MTTR) and overall equipment effectiveness (OEE). The objective of the analysis was to verify the correctness of determination of the above indicators in the analysed company. In addition, the study was to determine whether the use of correctly determined indicators and results interpretation could lead to a higher effectiveness of the actions taken by the maintenance services department. Moreover, the paper presents a diagnosis of problems connected with incorrect determination and visualization of the above-mentioned indicators in the analysed company.

17

Verification of the Modernized Technological Process Through TPM Indicators

Michlowicz E., Smolińska K.

Logistics and Transport

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2018

|

Vol. 37, No. 1

61--68

EN

Storage of zinc wastes is associated with a high risk of environmental pollution. The way to manage the problem is using the waste materials in the transition process, the final product of which is the zinc oxide concentrate. Transition process is technologically complex and every failure to the discipline results in a large number of unscheduled stops. Such an issue was encountered by B. Recycling. An update of environmental regulations has forced a comprehensive modernization of the technology lines used. The implementation of new solutions brought the necessity of examination and evaluation of the effectiveness of the process. In the paper the analysis conducted for this purpose are described. The elements of TPM method were selected as the test method. The OEE, MTBF and MTTR values for the individual process lines and additionally for the most problematic subassemblies were determined basing on the research and collected data.

18

Ocena efektywności wykorzystania linii produkcyjnej sprzętu AGD z wykorzystaniem wskaźnika OEE

Popielarz M., Knop K.

Archiwum Wiedzy Inżynierskiej

|

2018

|

T. 3, Nr 2

15--18

PL

W artykule przedstawiono wyniki w zakresie oceny efektywności wykorzystania linii produkcyjnego sprzętu AGD. Do oceny efektywności wykorzystano podstawowy miernik w koncepcji TPM - Kompleksowego Utrzymania Maszyn, tj. wskaźnik OEE. Kalkulacji wskaźnika OEE dokonano z wykorzystaniem darmowego kalkulatora do obliczeń i symulacji wskaźnika OEE firmy Neuron dostępnego na stronie internetowej: http://www.neuron.com.pl/pliki/kalkulator_oee.zip. Analizy efektywności dokonano dla 5 dni pracy badanej linii. Następnie w oparciu o uzyskane wyniki przedstawiono również średni poziom wykorzystania OEE. Analiza wykazała, że poziom efektywności pracy linii mierzony OEE zawiera się w granicach 59,97-88,39%, co należy uznać za wynik zadawalający a nawet dobry. Decydujący wpływ na obniżenie poziomu efektywności miała dostępność czasowa linii, a w szczególności awarie wyposażenia w linii. Zaproponowano działania mające na celu ograniczenie liczby awarii. Zaproponowano skorzystanie z techniki „5 x dlaczego” celem poznania, za każdym razem, przyczyny źródłowej awarii oraz zaproponowania skutecznych działań zaradczych. Należy też w pełni wykorzystywać potencjał grup roboczych złożonych z operatorów maszyn i pracowników działu utrzymania ruchu w identyfikacji przyczyn źródłowych awarii i przeciwdziałaniu ich ponownego wystąpienia.

EN

The article presents the results in the field of assessment of the effectiveness of the use of the household appliances production line. The basic measure in the concept of TPM - Total Productive Maintenance, i.e. the OEE indicator, was used for the effectiveness assessment. OEE calculation was made using a free calculator for calculations and simulations OEE, the company Neuron, available on the website: http://www.neuron.com.pl/pliki/kalkulator_oee.zip. Effectiveness analysis were performed for 5 days of operation of the tested line. The analysis showed that the level of work efficiency of the line measured with OEE is within 59.97-88.39%, which should be considered satisfactory and even good result. The time availability of the line, in particular equipment failures in the line, had a decisive impact on the reduction of the effectiveness level. Actions have been proposed to limit the number of failures. It was proposed to use the "5 x why" technique in order to learn, each time, the causes of the source failure and to propose effective remedial actions. It is also necessary to fully use the potential of working groups composed of machine operators and employees of the maintenance department in identifying the source causes of failures and preventing their recurrence.

19

Optimization of the production process execution through the implementation of Manufacturing Execution System

Rut J., Bartoszuk M.

Advances in Manufacturing Science and Technology

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2018

|

Vol. 42, nr 1-4

79--85

EN

Management of production processes in modern enterprises is a very complex issue. Efficient and effective functioning of enterprises is possible through optimization and automation of production processes. The proper organization of production processes and the ability to adapt to continuous changes in the business environment provide a competitive edge for a company. This article presents the optimization of the manufacturing process execution through the implementation of the Manufacturing Execution System in the audited company and the effects of changes as well as resulting benefits. The system of the MES class implemented in the company has contributed to improvement of many areas of company's operations.

PL

Zarządzanie procesami produkcyjnymi w nowoczesnych przedsiębiorstwach jest złożonym zagadnieniem. Sprawne i efektywne funkcjonowanie przedsiębiorstw jest możliwe dzięki optymalizacji i automatyzacji procesów produkcyjnych. Odpowiednia organizacja procesów produkcyjnych i umiejętność dostosowania się do ciągłych zmian w środowisku biznesowym zapewnia przewagę konkurencyjną dla firmy. W artykule przedstawiono optymalizację procesu produkcyjnego poprzez wdrożenie Systemu Zarządzania Produkcją w firmie oraz określono efekty zmian, także wynikające z nich korzyści. System klasy MES wdrożony w firmie przyczynił się do poprawy wielu obszarów jej działania.

20

Use of work station performance indicator rating in the manufacturing processes improving

Milewska E., Kossowska K.

Systemy Wspomagania w Inżynierii Produkcji

|

2017

|

Vol. 6, iss. 4

130--139

EN

The study presents the results of the research on improving the productivity of works executed of the up to 1400 mm conveyor belts fabrication workstation in Conbelts S.A. with its registered office in Bytom. Using the OEE indicator, the author conduct a performance evaluation of the work stations of the selected technology line. The results of the research have enabled us to design and implement solutions that eliminate irregularities and streamline the operation at the belt fabrication workstation. The post-implementation performance evaluation confirmed the effectiveness of the solutions taken.

PL

W artykule przedstawiono wyniki badań dotyczących poprawy wydajności prac realizowanych na stanowisku konfekcji taśm przenośnikowych tkaninowych do szerokości 140 mm w przedsiębiorstwie Conbelts S.A. z siedzibą w Bytomiu. Wykorzystując wskaźnik OEE autor wykonał ocenę wydajności stanowisk roboczych wybranego ciągu technologicznego. Uzyskane wyniki badań umożliwiły zaprojektowanie i wdrożenie rozwiązań eliminujących nieprawidłowości oraz usprawnienie działań realizowanych na stanowisku konfekcji taśm. Powdrożeniowa ocena wydajności potwierdziła skuteczności podjętych rozwiązań.