An Experimental Analysis On Overall Equipment Effectiveness

Volume 7, Issue 7, July – 2022 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
An Experimental Analysis on Overall

Equipment Effectiveness
D Karibasavaraja1, Bindhu A S2, Ramesh M R3, Sharnappa Joladarashi4
1
Assistant Professor, Dept. of Industrial and Production Engineering
2
Assistant Professor, Dept. of Mechanical Engineering
3
Associate Professor, Dept. of Mechanical Engineering NITK, Surathkal4Associate Professor,
Dept. of Mechanical Engineering NITK, Surathkal
1,2
Sri Jayachamarajendra college of Engineering, JSS Science and Technology University, Mysuru
Abstract:- Overall Equipment Effectiveness (OEE) is an Many aspects of OEE have been considered as, states that the
indicator to assess the utilization of machinery. This definition of OEE does not take into account all factors that
paper's primary goal is to identify and solve the loss reduce the capacity utilization, Bangar, Hemlatasahu et al. [5]
elements to enhance the Performance efficiency & Man He had done a case study in Jamna auto industry to improve
time. This study aimed at carrying out Gemba walk in the OEE (Overall Equipment Effectiveness) by implementing
industrial set up to analyse the problems faced by the Total productive maintenance. After that they reduce 80%
machine operator and continuous improvement solutios problem analyzed by Pareto chart and OEE of industry
were suggested for the performance enhancement. improved up to 96%. Binoy Boban et al. [6] Proposed a plan
to implementation TPM through the various pillars of TPM.
I. OBJECTIVE They had discussed the 5S and kaizen among the various
pillars, After a small implementation of TPM in company,
 To determine the Six Big Losses of Total Production they foundthat the OEE is increased by 4% and also it had
Management and decrease or eliminate them. been noted that the change in maintenance policy in the
 To achieve the greatest investment return in the shortest company changed their performance and quality Harsha G et
amount of time and al. [7] He had done a case study in improving the breakdown
 To maximize workforce productivity with a real-time, losses of machines through the implementation of TPM in the
achievable target company OEEand through effective implementation of TPM
techniques such as Preventive Maintenance, Cleaning with
II. METHODOLOGY Meaning, Pokayoke & Kaizen the OEE. Deniels [8] He
explains that the way to achievefundamental improvement on
The methodology involves the collection of data using the shop floor is to enable operators to establish their own
Gemba walk technique and analyze using Ischikawa Cause measures, toalign business strategies and to use them to drive
and Effect Diagram. The data has been collected in house in their Kaizen activities Teian [9] He describesthat Kaizen is
thefactory and it aims at action plans to be taken to enhance more than just a means of improvement because it represents
OEE. the daily strugglesoccurring in the workplace and the manner
in which these struggles are overcome. Kaizen can be applied
III. LITERATURE SURVEY to any area in need of improvement. Hammer et al [10] He
explains that Kaizen generates process-oriented thinking since
Huang S H et al. [1] In this paper the companies to processes must be improved before better results are obtained.
implement various productivity improvement efforts. Improvement can be 54 The Icfai University Journal of
Implementation of total productive maintenance TPM Operations Management.
techniques has led to significant productivity improvements
for individual equipment. an approach, based on overall IV. CURRENT STUDY
equipment effectiveness OEE, is developed to model the
productivity of a manufacturing system in terms of overall  Types of defects in injection moulding components
throughput effectiveness OTE. Mark C et al. [2] In this paper
he put a strategy stating that developing society needsto adapt  Short Shots = Short shoots are an occurrence where the
to change and foster creativity. In the pursuit of continual Cavity for mould cannot be completely filled.
improvement, he productivity improvements achieved at the
equipment level are significant but insufficient because what
a companyreally needs is a highly efficient system/factory.
This is especially true in the discrete manufacturing industry
Huang et al. [3] In the Report that the concept of OEE is
becoming increasingly popular and that it has been widely
used as a quantitative tool essential for the measurement of
productivity in semiconductor manufacturing operations.
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ISSN No:-2456-2165
Causes: (1) Conditions that are too dry are not ideal; employ
a lot of recycled materials (2) incorrect setting for the
injection temperature (3) The settings for the gate and runner
system are incorrect. (4)The melting mark's tensile strength is
low.
 Burn Marks
The burn scars are caused by the inability of the cavity's
gas to be quickly expelled, which results in blackening at the
flow's termination.
Fig 4.12.1 Short shorts in component
Causes: (1) Die temperature, injection pressure or material

temperature and the speed is too slow (2) uneven raw
materials plasticization (3) shoddy exhaust (4) inadequate
raw material liquidity.
 2. Air trapped inside a cavity to produce bubbles in the

component is known as an air trap.
Fig 4.12.5 Burn Marks in component
Causes: (1) It is impossible to swiftly remove the cavity's air.

(2) Material degradation includes an excessively high melt
temperature, an excessive cast screw speed, and a poorly
designed runner system.
 Flash
It denotes the presence of extra plastic on the ejector or
mould separation.
Fig 4.12.3 Short shorts in component
Causes: When the two melt fronts collide, it results from the
air being unable to escape from the dividing surface, the ram,
or the vent.
 Brittleness
Brittleness refers to how quickly a plastic component
can crack or break.
Fig 4.12.6 flash in component
Causes: (1) inadequate gripping pressure (2) The mould is

flawed. (3) The hilling.
 Warpage
The war page is the most challenging issue to address in
the design and production of plastic parts.
Fig 4.12.4 Brittleness in component

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 Insufficient clamping force
 The mould has defects
 The mounding.
Flash on part surfaces can be caused by a variety of

underlying factors. Many are caused by the mould itself, but
others can be made up for by changing the material or
injection machine used:
 Mould Wear Problems

A worn-out or outdated mould that no longer fits tightly
together and allows the plastic to leak out is the most frequent
Fig 4.12.7 Warpage in components problem that results in flashing. By repairing or redesigning
the mould, this is addressed.
Causes: (1) Pouring, chilling, and ejection systems comprise
the mould structure. (2) Product structure: Changing the wall  Mould Design Problems
thickness of plastic parts, having curved or asymmetrical A mould can simply be badly constructed, with gaps that
geometry, ribs, and using an unreasonable BOSS column lead to flashing, pressure problems brought on by the usage
design (3) The plastic pieces are not totally cooled during of many parts, or unnecessarily complicated geometries that
production, and the injection and pressure holding curves are result in poor fits. It could be necessary to redesign or retool
irrational. (4) Plastic materials: Plastic materials experience the mould.
shrinkage, even without additional fillers.
 Main root cause for defects and flash occurring  Pressure and Flow Problems
Flash may signal pressure or temperature problems in
the mould. Dealing with the problem may be made easier by
 Flash redesigning the mould with better gates or hot runners.
A part may flash for a variety of reasons, including as
changes in the process or material or tooling issues. Flash
appears on the edge of the part along the mould's parting line  Clamping a mould
or wherever the metal in the mould contacts metal to establish Last but not least, the problem can be that the plates are
the component's border. Recognizing what type of flash you not secured firmly enough to prevent glue from pushing its
are getting and when it is occurring will help you find the way between plates. This problem can be resolved by
source, which is usually the tool. increasing the clamping force of the plate or by transferring
the mould to a machine with a stronger clamp.
 Layout optimization to reduce the bin travelling time
Fig 4.17.5 existing bin travelling movement

ISSN No:-2456-2165
Operations layout plays a significant role in the game to create a lean flow and to maximise production from various areas or
processes that take place in a warehouse. Using a good procedure in the wrong layout might have negative effects on the area and
the business as a whole:
 Bottlenecks
 Slow down the productivity
 Rejections
 Product losses
 Disorganization
 Analysis of the Area's Current Process

Knowing the warehouse's overall process is vital to make sure the operation of the area to be defined is consistent with and
adaptable to the overall process, but it is also necessary to know the specific and detailed activities that take place in the area where
the layout is going to be defined.It is crucial to assess the defined process and determine whether it is the right one before beginning
to investigate the plant dispersion.
 Problem solved in cover fan mould and design specification forsolving the problem
Fig 4.18.1(a) before solving Fig 4.18.2(b) after solving problem
 Reason for the flash in component

Due to some dents in the core pin’s work material entering some area around the dent area. Due todents in the core, it’s not
properly assembled with the cavity. Due to improper in assembly it createsair gap between Core and cavity. Work material will enter
in that air gap and create flash.
Fig 4.18.3 Core of Cover Fan
A tool called a fan cover core is used in moulding procedures to create internal cavities and re-entrant angles (interior angles
higher than 180 degrees). In order to remove the core from the piece, it is often a disposable item that is destroyed. They are employed
most frequently in, although they are also employed in die casting and injection moulding.

ISSN No:-2456-2165
 Design specification of core
Fig 4.18.4 Top view of core
 Side View of core
Fig 4.18.5 side view of core
Standard Dimension of Gateway Actual dimension of gateway
Above fig shows that the difference between standard dimension to the actual dimension in the mould gateway. Actual gateway
is not having same dimensions in all its gateway area this problemis obtained due to bend in its pins and some of pins are ware out.
Due to this problem the work material is entering some places the material was not suppose to enter, due to this the flash is obtains.

ISSN No:-2456-2165
 Radius of each pin’s to its parallel pin
Standard Dimension Actual dimension
Above fig shows that the difference between radius of each pin’s to its parallel pin. In the standard arrangement of pins diameter
of parallel pins are same to all, but in the Actual arrangement of pins it is not same in all pins. This problem is obtained due to bend
tn the pinsand ware out of pins.
 Problem solved in head lamp housing mould and design specification for solving theproblem
Fig 4.19.1 before solving problem Fig 4.19.2 after solving problem
Fig 4.19.3 before solving problem

ISSN No:-2456-2165
Fig 4.19.4 after solving problem
 Reason for flash in component

In Headlamp housing we identify the problem in side core and front pins. In side core hole pin wasware out and it not helping
to create holes in side of the headlamp, and same problem occurred in the front pin its dimensions are reduced because of ware and
tare in the pin due to mould movement.
Fig 14.19.5 Side Core
The mold's side core is a component. For the purpose of creating a hole or recess in the side face of a moulding, a sliding core
is a local core that is typically positioned at a right angle to the mould axis. This side core prohibits the moulding from being
removed in-line, hence a method must be given to remove the side core before ejection It is employed in this mould to enlarge the
component's holes.
 Design specification of side core
Top view
Fig 4.19.6 (a) Standard dimension

ISSN No:-2456-2165
 Dimension of side core with punch pin
Fig 4.19.7 (b) Actual dimension
1. Fig 4.19.6 (a) standard dimension

2. Fig 4.19.7 (b) actual dimension
Shows that the dimension of the standard pin and the actual pin. Fig 3.5 shows 4mm in length and2mm in diameter difference
in actual to standard pin, so in this case the pin has to be removed andreplaced.
 Dimensions of standard and actual punch pin
Fig 4.19.8 (a) Standard pin size
Fig 4.19.9 (b) Actual pin size
Above Fig 3.6 and 3.7 shows that the dimensions of punch pin. Mould has 2 pins in front in those2 pinswas ware out as shown
above. The front end of the pin was ware out by 2.65mm in length. In this case we can rework the pin and make the pin acceptable
dimension.

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 Problem solved in deflector mould and design specification for solving problem
Fig 4.20.1(a) before solving problem Fig 4.20.2(b) after solvingproblem
Deflector is a component which attaches with air filter assembly used attachment for deflecting flowof air, heat.
 Reason for flash in component
Due to were and tear in pin in the core, the hole is not obtaing properly. This is the reason whythe work material centering
to the hole, and creating flash in that area.
 Design specification of side core
Fig 4.20.3(a) Standard pin size Fig 4.20.4(b) Actual pin size
 Kaizen for layout optimization to reduce bin travelling movement Existing bintravelling movement
Fig 4.23.1(a) existing bin travelling movement

ISSN No:-2456-2165
Operations layout plays a significant role in the game to create a lean flow and to maximise production from various areas or
processes that take place in a warehouse. Using a good procedure in the wrong layout might have negative effects on the area and
the business as a whole:
 Bottlenecks
 Slow down the productivity
 Rejections
 Product losses
 Disorganization
 Analysis of the area's present procedure

To define a good layout, it is necessary, on one hand, to know the global process of the warehouse, to ensurethe operation of the
area to be defined is coherent and adapted to the global process, and on the other hand, to know the specific and detailed activities
of the area where the layout is going to be defined. Before startingto study the plant distribution, it is important to analyze the defined
process and evaluate if it is the appropriate one.
 Optimized bin travelling movement
Fig 4.23.2 (b) optimized bin travelling movement
Use of optimization  The significance of design

 Short fill problems can be reduced Understanding the impact of an effective layout on the
manufacturing function will help one better comprehend the
 Part rejections can be reduced significance of a layout: It makes it efficient and fluid. A
 Travelling time for bin can be reduced correct layout is essential for operating efficiencies such as
 Equal and average distance in optimized layout reduced material handling costs, reduced production delays,
and avoided bottlenecks.
 smallest motions
The process of an area in a warehouse frequently  Advantages of optimized layout
involves numerous steps; It could be viewed as a series of
tasks that must be completed in order to fulfill the activity's  Savings in handling
main goal. To go to the following level, the item and the Material handling costs contribute for between 30 and
operators must be moved multiple times. Although they don't 40 percent of the cost of manufacturing. Therefore, every
provide much value, these motions are important to transport effort should be taken to reduce this expense. Avoid long
commodities from one station to another.Consequently, it is distance moves, and stop using specific handling techniques.
the goal to minimize them as much as feasible. The less A cynic would assert that the cheapest method of handling
moves made, both in terms of quantity and distance, the materials is to do nothing at all. However, a factory requires
quicker this important but unproductive chore can be the handling of materials, thus everything is dependent on the
completed. plan.

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 Effective use of the space available inadequate storage space or low speed on part of the
Especially in metropolitan environments, every square operators. The results of bottlenecks are delays in productions
inch of the plant space is valuable. Therefore, it is important schedules, congestion, accidents and wastage of floor area.
to make an effort to utilize the space by carefully designing All these may be overcome with an efficient layout.
the arrangement. Putting equipment and services in strategic
locations where they can serve many purposes is one way to  Better production control
accomplish this goal; creation of modern workspaces and Production Control is concerned with the production of
operator job descriptions to fully use the labor force. the product of the right type, at the right time and at a
reasonable cost. A good plant layout is a requisite for good
 Decrease in production delays production control and provides the production control
Prompt order execution will lead to repeat business and officers with a systematic basis upon which to build
new clients. The delivery timetables should be adhered to by organization and procedures.
all management. The delivery deadlines for production orders
are frequently a management headache. An important aspect  Better supervision
in the prompt execution of orders is plant layout. An ideal A good plant layout ensures better supervision in two
plan avoids delays due to lack of space, lengthy material ways:
transportation, and spoilt work, which helps with the quick  Determining the number of workers to be handled by a
completion of orders. supervisor and 2.Enabling the supervisorto get a full view
of the entire plant at one glance.
 Enhanced quality assurance
Orders will only be meaningfully completed on time if  Improved employee morale
the output quality meets or exceeds expectations. To ensure Employee morale is achieved when workers are
quality, inspection should be conducted at different stages of cheerful and confident. This state of mental condition is vital
manufacture.An ideal layout provides for inspection to ensure to the success of any organization.
better quality control.
 Plant layout has a bearing on all these
 Lowest equipment expenditure Avoidance of Unnecessary and Costly Changes a
By installing general-purpose machines, planning planned layout avoids frequent changes which are difficult
machine balance and position, minimizing handling and costly.
distances, and planning machine loading, equipment
investment can be reduced. All these benefits are provided by V. RESULTS AND DISCUSSION
an effective plant layout.
 Time Study Before Maintenance Of Mould
 Avoidance of bottlenecks As the time study data was collected we found that
Bottlenecks refer to any place in a production process deflashing operation consumes more time in total Man time,
where materials tend to pile up or are produced at a speed, when the Man time exceeds more time than the Actual
less rapid than the previous or subsequent operations. running time then the production rate and the performance
Bottlenecks are caused by inadequate machine capacity, efficiency decreases of the worker.
Table 5.1 Time study sheet before maintenance

SI No. 1 2 3 4 5 6
Part no 2184H1270 2184H0690 2184D0170 2184T0750 2184H1260 2184C4560
Head lampfront DeflectorRH/LH Tail CoverLUG HousingFan Cover FuelTank

Part name Cover Fan RH- Outer
LH
PED time 40 35 28 45 75 55
Actual running 45 37 34 55 50 49
Difference PED 1 9 6 10 -25 6

actual
Deflash 30 24 15 13 36 35
Man time 50 46 34 24 65 53

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 Time study after maintenance of mould
As we worked on how to control the flash which is waste of deflashing time, After the preventive maintenance of the mould
tool we assume that it will reduce the deflashing timeup to 50-60% as of before which will reduce the total Man time then the Actual
running time. This will improve the production rate and performance efficiency of the worker.
Table.5.2 Time study sheet after maintenance

SI No. 1 2 3 4 5 6
Part no 2184H1270 2184H0690 2184D0170 2184T0750 2184H1260 2184C4560
Part name Cover Fan Head lampfront DeflectorRH/LH Tail CoverLUG HousingFan Cover FuelTank
RH- LH Outer
PED time 40 35 28 45 75 55
Actual running 45 46 34 55 50 49
Difference PED 1 11 6 10 -25 6
actual
Deflash 10 12 5 8 18 10
Man time 40 25 24 24 65 53
 After plant workshop optimization
Fig 5.3 Plant Workshop Optimization
After the optimization of the plant workshop layout, this will reduce the maximum distance and Man time for the right side
machine workers, which will increase the productivity and performance efficiency of the worker.
 After optimization of plant work shop

 Short fill problems is reduced
 Part rejection due to short fill is reduced
 Travelling time for bin is reduced for all the lines
 Equal and average distance
 Increase the productivity and performance efficiency of the worker.
 Helps to reduce the man time and indirectly helps to increase the OEE

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Table shows the difference between optimized and un optimized binarea
Table 5.3 Man time of bin movement for before and after optimization
Man Time
Machines Time to get 12 empty bins in sec
Before After Difference
JSW 550 I 200 50 150
FC 420 II 220 60 160
JSW 450 II 220 60 160
KL 450 II 230 70 160
JSW 450 I 240 80 160
KL 450 I 250 80 170
MAX 650 II 250 80 170
FC 620 240 80 160
MAX 650 I 230 70 160
MAX 650 V 220 70 150
MAX 650 IV 220 60 160
SM 620 I 200 60 140
MAX 650 III 200 60 140
FC 60 280 100 180
FC 150 IV 290 120 170
FC 220 II 300 130 170
FC 220 IV 300 150 150
JSW 140 320 170 150
FC 330 330 180 150
FC 350 330 180 150
JSW 220 340 210 130
 Time consumed before and after optimization
Fig 5.5 histogram for optimization bin area
The histogram represents the optimization of bin area in x axis it represents the machine and Y axis representstime in seconds.
We can see that the time has been balanced.

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Total time consumed before and after optimization
Fig 5.6 Comparison of time in seconds before and after optimizing
The graph shows time consumption in seconds the blue indicates the before optimization timewas taking around 66% and
yellow indicates the after-optimization time was taking around 34% we cansee that time has been optimized 32%.
 Before maintenance PED, actual time & man time for the followingcomponents
Fig 5.7.1 histogram for cover fan
In the histogram X axis represents the PED time, actual time, man time and Y axis represents time in seconds. In graph we can
see that man time 50 sec is exceeding the actual time 45sec which results in theloss of OEE.
Fig 5.7.1 histogram for cover fan

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In graph we can see that man time 46 sec is exceeding the actual time 37 sec which results intheloss of OEE.
Fig 5.7.3 histogram for Deflector
In graph we can see that man time 34 sec is exceeding the actual time 34 sec both the timehasbeen balanced but the OEE
cannot be achieved.
 After maintenance PED, actual time and man time for the followingcomponents
Fig 5.8.1 histogram for Cover fan
In graph we can see that man time 40 sec is not exceeding the actual time 45 sec it hasoptimized up to 5 sec which
helps achieve the OEE.
Fig 5.8.2 histogram for Head lamp front
In graph we can see that man time 25 sec is not exceeding the actual time 46 sec it hasoptimized up to 21 sec which

ISSN No:-2456-2165
Fig 5.8.3 histogram for Deflector
In graph we can see that man time 24 sec is not exceeding the actual time 34 sec it hasoptimized up to10 sec which
VI. CONCLUSION [7]. Harsha G. Hegde, N. S. Mahesh, and Kishan Doss,

“Overall Equipment Effectiveness Improvement by
The initiative provides the business with a new, TPM and 5S Techniques in a CNC Machine Shop”,
significant step in improving performance efficiency. When SASTECH , vol. 8, no. 2, pp.25-32, 2009.
we came together as a group, the organization had the [8]. Deniels R C (1996), “Profit-Related Pay and
opportunity to observe how crucial teamwork is to solving Continuous Improvement: The Odd Couple”,
difficulties. To determine the Six Big Losses of Total Engineering Management Journal, Vol. 6, No. 6, pp.
Production Management and decrease (or perhaps eliminate) 233-236.
them. To maximize return on investment in the shortest [9]. Teian K (1992), Guiding Continuous Improvement
amount of time possible. To increase employee productivity Through Employee Suggestions, Productivity Press,
It might offer operators a live, attainable goal. The Portland, US.
opportunity to learn about the top methods they can use to [10]. Hammer M, Champy J and Tathan R L (1993),
enhance their performance is another advantage of the Reengineering the Corporation: A Manifesto for
project.Enhancing OEE also enables the business to identify Business Revolution, Harper Collins, New York.
its strengths, weaknesses, and improvement opportunities.
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R.B.; Robinson, D.E (2003): “Manufacturing
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An Experimental Analysis On Overall Equipment Effectiveness

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Volume 7, Issue 7, July – 2022 International Journal of Innovative Science and Research Technology

An Experimental Analysis on Overall

IJISRT22JUL1314 www.ijisrt.com 1499

Fig 4.12.1 Short shorts in component

Causes: (1) Die temperature, injection pressure or material

 2. Air trapped inside a cavity to produce bubbles in the

Fig 4.12.5 Burn Marks in component

Causes: (1) It is impossible to swiftly remove the cavity's air.

Fig 4.12.3 Short shorts in component

Fig 4.12.6 flash in component

Causes: (1) inadequate gripping pressure (2) The mould is

Fig 4.12.4 Brittleness in component

IJISRT22JUL1314 www.ijisrt.com 1500

Flash on part surfaces can be caused by a variety of

 Mould Wear Problems

 Layout optimization to reduce the bin travelling time

Fig 4.17.5 existing bin travelling movement

IJISRT22JUL1314 www.ijisrt.com 1501

 Analysis of the Area's Current Process

Fig 4.18.1(a) before solving Fig 4.18.2(b) after solving problem

 Reason for the flash in component

Fig 4.18.3 Core of Cover Fan

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Fig 4.18.4 Top view of core

 Side View of core

Fig 4.18.5 side view of core

Standard Dimension of Gateway Actual dimension of gateway

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Standard Dimension Actual dimension

Fig 4.19.3 before solving problem

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Fig 4.19.4 after solving problem

 Reason for flash in component

Fig 14.19.5 Side Core

 Design specification of side core

Fig 4.19.6 (a) Standard dimension

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Fig 4.19.7 (b) Actual dimension

1. Fig 4.19.6 (a) standard dimension

 Dimensions of standard and actual punch pin

Fig 4.19.8 (a) Standard pin size

Fig 4.19.9 (b) Actual pin size

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Fig 4.20.1(a) before solving problem Fig 4.20.2(b) after solvingproblem

 Reason for flash in component

 Design specification of side core

Fig 4.23.1(a) existing bin travelling movement

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 Analysis of the area's present procedure

 Optimized bin travelling movement

Fig 4.23.2 (b) optimized bin travelling movement

Use of optimization  The significance of design

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Table 5.1 Time study sheet before maintenance

Head lampfront DeflectorRH/LH Tail CoverLUG HousingFan Cover FuelTank

Difference PED 1 9 6 10 -25 6

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Table.5.2 Time study sheet after maintenance

 After plant workshop optimization

Fig 5.3 Plant Workshop Optimization

 After optimization of plant work shop

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 Time consumed before and after optimization