Integrated Overall Performance Effectiveness (OPE) And Simulation For Flexibility Enhancement During Changeover In Production Assembly Process

Kua, Ning Way (2018) Integrated Overall Performance Effectiveness (OPE) And Simulation For Flexibility Enhancement During Changeover In Production Assembly Process. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Todays, the manufacturing industry has come to revolution of Industrial 4.0. This new paradigm has leads the complex market demand, all manufacturers needed to compete in the global market place. Hence, multi-product companies are required to be more flexible in their operation to fulfil the demand of the market. These reveal to companies the necessity of improving the changeover or setup performance to provide fast response to customer demands. This paper aims to highlight the possible improvement for the overall productivity of the production system by lowering the changeover time using Overall Performance Effective (OPE). To that end, an industrial case study is conducted on an electronic and mechanical assembly production plant which is Likom. A 37.58% increment in OPE was attained. To attain the objective of reducing the changeover time, a virtual production plant model is developed by using ARENA simulation to analyse the productivity after the proposed method is applied to the production line. The output of the simulation shows that the productivity is increased by 16.67%. Results therefore indicate that OPE measurement is an effective way to analyse the efficiency of a single setup process. By using the same logic model, analysis of variability is performed to predict the productivity without the need to change the existing line. Decision Support System (DSS) framework are established to assist the company make a decision on improvement planning.

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