The theme of this issue is the expression of "equipment stop" and "loss".
In the TPM(Total Productive Maintenance), among 16 factors that impede the efficiency of production activities, 7 losses which impede equipment efficiency are called 7 losses, and these are cited as follows.
(1) Shutdown loss (scheduled shutdown)
(2) Failure loss
(3) Setup & Adjustment loss
(4) Blade replacement loss
(5) Startup loss
(6) Brief stop & Spin loss
(7) Failure & Repairing loss
When designing a production system, it is necessary to evaluate beforehand about how much the facility efficiency will be achieved after taking into consideration the above losses, and to reflect it in realistic production planning.
In this issue, we explain how to represent setup & adjustment loss among 7 big losses with GD.findi.
- Tooling Activity
In GD.findi, it is necessary to set the tooling activity in order to express "setup & adjustment loss".
Tooling activity indicates an activity which is dealing with tools such as molds and jigs, and because it is not directly linked to product production activities, so it is not defined in the process plan.
Tooling activity is treated as work related to station activity.
- Example of mold change
Here, taking press processing as an example, we consider replacing the mold implemented at the time of product change in the facility for various types of production. For mold replacement, it takes 15 minutes for installation and 10 minutes for removal.
1. Create floor plan and process plan
We set up two products as the manufacturing process below.
Product A: press processing A1 (30 seconds) --> press processing A2 (20 seconds)
Product B: press processing B1 (50 seconds) --> press processing B2 (40 seconds)
In this example, it is assumed that in the facility 1, mold replacement is implemented at the time of product changeover.
2. Create a production plan
We set up a production plan as below.
We produce 50 products in total by producing 10 product per product.
3. Set the tooling master
Set the tooling master before setting tooling activities.
Register the type and number of molds to be used on the line.
Here we prepare three molds for each mold A and mold B.
4. Set tooling activity
First, add a new tooling activity
From the activity screen, right-click on the station activity and select [Add Tooling Activity], and a new tooling activity will be created.
Next, set the parameters of the activity.
Set two tooling activities for press processing A1 and press processing B1 as follows.
* The station activity of press processing B1 is displayed by selecting "Product B" from the [Product: ] pulldown in the upper right side.
GD.findi can correctly handle with competing issues of resources in activities.
For instance, if an operator in charge of setup is implementing another activity, the setup worker does not start the work until the operator arrives.
Also, for example, if one mold is shared by multiple processes, it will not be possible to start the setup work until the mold is released from the other processes.
5. Confirmation of simulation execution result
If you check with the material flow, you can find that equipment stoppage has occurred every time when the producing product changes.
* The flow of the top part of lot is displayed as a flow line.
By utilizing the functions introduced this time, we can conduct more accurate simulation in consideration of loss in multi-product production.
Please use it by all means.
For more details regarding GD.findi, please find the webpage or contact GD.findi email address as below.
Inquiry address: firstname.lastname@example.org