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PRODUCTIVITY IMPROVEMENT

TECHNIQUES

HEMANT PATIL
MCM04
CONTENTS

PRODUCTIVITY
PRODUCTIVITY IMPROVEMENT
PRODUCTIVITY IMPROVEMENT TECHNIQUES
AUTOMATION
CASE STUDIES
PRODUCTIVITY

Inputs Output
transformations Customers
Land Goods
people SYSTEM and
capital services
facilities
equipment
tools O
energy I
materials
information productivity
PRODUCTIVITY IMPROVEMENT

• Increase output while input remains same


• Decrease input while output remains same
• Increase input resulting in a very large increase in
output
• Decrease input by a very large amount with a
resultant small reduction in output
PRODUCTIVITY IMPROVEMENT
TECHNIQUES
• CAD/CAM
• CIM
• ROBOTICS
• SHIGEO SHINGO PRINCIPLES
• GROUP TECHNOLOGY
• JOB ROTATION
• TQC
CAD/CAM
CAD
A software system that uses computer graphics to assist in
the:
• Creation
• Modification
• analysis of a design

CAM
Use of computer system to plan, manage and control the
operation of a manufacturing plant through either direct
or indirect computer interface.
COMPUTER INTEGRATED
MANUFACTURING
• CIM is the architecture for integrating the
engineering, marketing, and manufacturing
functions through information technologies.
ROBOTICS
• “A robot is a reprogrammable, multifunctional
manipulator designed to move material, parts,
tools, or specialized devices through variable
programmed motions for the performance of
a variety of tasks.”
SHIGEO SHINGO PRINCIPLES
Dr. Shingo Shigeo’s teachings can be classified
into the three concepts listed as follows.
• Just In Time (JIT).
• Single Minute Exchange of Dies (SMED).
• Zero Quality Control.
JIT
“JUST IN TIME”
• A philosophy of manufacturing based on
planned elimination of all waste and
continuous improvement of productivity.
SMED
SINGLE MINUTE EXCHANGE OF DIE

• It is one of the world class manufacturing


techniques. By implementing the Set up
Reduction, we can reduce waste time during
machining and hence we can improve our
production rate on that machine.
Zero Quality Control
Dr. Shigeo Shingo’s Zero Quality Control (ZQC)
techniques make use of the following
engineering principles:
 100 percent inspections done at the source
instead of sampling inspections
 Immediate feedback from successive quality
checks and self checks
GROUP TECHNOLOGY
• Group technology is a manufacturing
philosophy in which similar parts are identified
and grouped together to take advantage of their
similarities in manufacturing and design.
JOB ROTATION
Job rotation is a management technique that
assigns trainees to various jobs and departments
over a period.
Job Rotation is frequently used with new trainees
who are just entering the workforce. Trainees
gain perspective on various areas of the
organization. This provides an opportunity to
work with higher management and different
departments.
TOTAL QUALITY CONTROL
Total-Made up of whole.
Quality-Degree of excellence of a Product or
service.
Management-Act,art,manner of handling
controlling directing etc.

TQM is an art of Managing the whole to


achieve excellence.
AUTOMATION

MANUAL OPERATED MACHINES SEMI-AUTOMATED MACHINES

AUTOMATIC MACHINES
CASE STUDY

PRODUCTIVITY WITH CONVENTIONAL


MACHINING AND ADVANCED TECHNIQUES
CHALLENGE

GEX’s leaders determined they would need to


improve profits 15 percent to 20 percent
without adding resources in order to maintain
their leading position.
SEWING LINE
BEFORE AUTOMATION AFTER AUTOMATION
CUTTING LINE
BEFORE AUTOMATION AFTER AUTOMATION
RESULTS
Modifying production line for productivity
improvement A Case Study of Vision Lens
Factory
OPERATION PROCESS CHART
PROCESS LAYOUT OF ASSEMBLY AND
FILLING STATION OF CURRENT LINE
PROCESS LAYOUT OF ASSEMBLY AND
FILLING STATION OF IMPROVED LINE
RESULTS
THANK YOU….