Manufacturing System Throughput Excellence : Analysis, Improvement, and Design

• Record Nr.: UNINA9911019653003321
• Autore: Tang He (Herman)
• Pubbl/distr/stampa: Newark : , : John Wiley & Sons, Incorporated, , 2024; ©2024
• ISBN: 9781394190355; 1394190352; 9781394190331; 1394190336
• Edizione: [1st ed.]
• Descrizione fisica: 1 online resource (339 pages)
• Disciplina: 658.5
• Soggetti: Process control; Production management; Production engineering; Industrial engineering
• Lingua di pubblicazione: Inglese
• Formato: Materiale a stampa
• Livello bibliografico: Monografia
• Nota di contenuto: Cover -- Title Page -- Copyright -- Contents -- List of Figures -- List of Tables -- About the Author -- Preface -- Acknowledgments -- About the Companion Website -- Chapter 1 Throughput Concepts -- 1.1 Introduction to Throughput -- 1.1.1 Role of Throughput on Business Success -- 1.1.1.1 Role of Manufacturing in Business -- 1.1.1.2 Financial Significance of Throughput -- 1.1.1.3 Work Focuses -- 1.1.1.4 Throughput Management -- 1.1.1.5 Throughput Work Collaboration -- 1.1.2 Manufacturing Throughput Performance -- 1.1.2.1 Basics of Throughput -- 1.1.2.2 Operational Availability -- 1.1.2.3 System Productivity -- 1.1.2.4 Considerations in Productivity -- 1.2 Discussion of Manufacturing Throughput -- 1.2.1 Characteristics of Manufacturing Throughput -- 1.2.1.1 Cost Perspective -- 1.2.1.2 Throughput and WIP -- 1.2.1.3 Continuous Improvement vs. Optimization -- 1.2.2 Time Analysis in Manufacturing Operations -- 1.2.2.1 Time Elements of Operations -- 1.2.2.2 Definitions of Cycle Time (CT) -- 1.2.2.3 CT and Throughput -- 1.2.2.4 Lead Time and ; Throughput -- 1.3 Characteristics of Manufacturing Systems -- 1.3.1 Overview of Manufacturing Process Types -- 1.3.1.1 Four Major Types of Processes -- 1.3.1.2 Comparison of Process Characteristics -- 1.3.2 Settings of Manufacturing System -- 1.3.2.1 Systems View and Configuration -- 1.3.2.2 System Composition -- 1.3.3 Additional Throughput Considerations -- 1.3.3.1 Throughput Performance Pillars -- 1.3.3.2 Throughput Improvement Potential -- 1.3.3.3 Issues in Batch Process -- 1.4 Operational States of Production -- 1.4.1 Operational States of Systems -- 1.4.1.1 Nonworking States -- 1.4.1.2 Discussion of Operational States -- 1.4.1.3 Additional Thoughts on Operational States -- 1.4.2 Applications of Standalone State -- 1.4.2.1 Standalone State Concept -- 1.4.2.2 Standalone Availability -- 1.4.2.3 Standalone TR.; 1.4.2.4 Discussion Examples -- Chapter Summary -- Exercise and Review -- Exercises -- Review Questions -- References -- Chapter 2 System Performance Metrics -- 2.1 Performance Measurement -- 2.1.1 Direct Throughput Indicators -- 2.1.1.1 Production Count and Rate -- 2.1.1.2 System Availability Metric -- 2.1.2 KPIs of Operations -- 2.1.2.1 Variety of KPIs -- 2.1.2.2 Discussion of KPI Applications -- 2.1.2.3 KPIs in Throughput Management -- 2.1.3 Review of ISO 22400 KPIs -- 2.1.3.1 Common KPIs -- 2.1.3.2 KPI Categorization -- 2.1.3.3 Throughput KPIs -- 2.2 Manufacturing System OEE -- 2.2.1 Three Major Metrics -- 2.2.1.1 Availability Element -- 2.2.1.2 Speed Element -- 2.2.1.3 Quality Element -- 2.2.2 Introduction to OEE -- 2.2.2.1 Concept of OEE -- 2.2.2.2 OEE Interpretation -- 2.2.3 OEE Studies -- 2.2.3.1 OEE Accuracy Analysis -- 2.2.3.2 OEE Change Estimation -- 2.2.3.3 OEE Benchmarking -- 2.3 Considerations on OEE -- 2.3.1 Weighting in OEE -- 2.3.1.1 Review of Existing Weighting -- 2.3.1.2 New Comparable Weighting -- 2.3.1.3 Interpretation of Weighted OEE -- 2.3.2 Standalone OEE -- 2.3.2.1 Calculation of Standalone OEE -- 2.3.2.2 Implementation of Standalone OEE -- 2.3.3 OEE Extensions -- 2.3.3.1 OEE for Labor Effectiveness - OLE -- 2.3.3.2 OEE with Time Utilization - TEEP -- 2.4 Further Discussion of KPIs -- 2.4.1 KPI Selection -- 2.4.1.1 Overall Selection Process -- 2.4.1.2 KPI Candidate Review -- 2.4.1.3 Additional Selection Considerations -- 2.4.2 Considerations in KPIs -- 2.4.2.1 Relations among KPIs -- 2.4.2.2 Relation between Subsystem and System KPIs -- 2.4.2.3 Subsystem-System KPI Relation Analysis -- 2.4.3 Financial Implications of KPIs -- 2.4.3.1 Relation between KPIs and Finance -- 2.4.3.2 Throughput Accounting -- 2.4.3.3 Justification for Throughput -- Chapter Summary -- Exercise and Review -- Exercises -- Review Questions -- References.; Chapter 3 Bottleneck Identification and Buffer Analysis -- 3.1 Understanding of Bottleneck -- 3.1.1 System Bottleneck -- 3.1.1.1 Concept of Bottleneck -- 3.1.1.2 Improvement on Bottleneck -- 3.1.1.3 Considerations in Addressing Bottleneck -- 3.1.2 Classification of Bottleneck -- 3.1.2.1 Performance and Capacity Bottlenecks -- 3.1.2.2 Time Characteristics of Bottlenecks -- 3.2 Bottleneck Identification -- 3.2.1 Identification using Individual KPI -- 3.2.1.1 By Operational Availability -- 3.2.1.2 By Throughput Rate and Cycle Time -- 3.2.1.3 By Active Period -- 3.2.1.4 By Starved and Blocked Time -- 3.2.2 Identification using Multiple KPIs -- 3.2.2.1 Examining Multiple Metrics -- 3.2.2.2 Using OEE and Standalone OEE -- 3.2.2.3 Considerations in Bottleneck Identification -- 3.2.3 Research on Bottleneck -- 3.2.3.1 Challenges of Bottleneck Identification -- 3.2.3.2 Research Methodology on Bottleneck -- 3.2.3.3 Bottleneck Analysis for Nonmanufacturing -- 3.3 Understanding of System Buffer -- 3.3.1 Buffer Effect of Conveyor -- 3.3.1.1 Function of Conveyor -- 3.3.1.2 ; Understanding of Buffer Effect -- 3.3.1.3 Discussion of Buffer Effects -- 3.3.2 Buffer Effect Analysis -- 3.3.2.1 Illustrative Effect Analysis -- 3.3.2.2 Consideration of Buffer Reliability -- 3.3.2.3 Characteristics of WIP on Buffer -- 3.4 Buffer Analysis for Bottleneck Identification -- 3.4.1 Considerations in Buffer Analysis -- 3.4.1.1 Buffer WIP Monitoring -- 3.4.1.2 WIP Change and Bottleneck -- 3.4.1.3 Discussion of WIP Changes -- 3.4.2 Analysis of Buffer Status -- 3.4.2.1 WIP Change Rate Calculation -- 3.4.2.2 WIP Distribution Analysis -- 3.4.2.3 Discussion of WIP Distribution -- Chapter Summary -- Exercise and Review -- Exercises -- Review Questions -- References -- Chapter 4 Quality Management and Throughput -- 4.1 Quality Management -- 4.1.1 Understanding of Quality.; 4.1.1.1 Common Definitions of Quality -- 4.1.1.2 Dimensions of Quality -- 4.1.1.3 Quality and Operational Excellence -- 4.1.1.4 Manufacturing Quality -- 4.1.2 Quality Management System -- 4.1.2.1 Key Elements of QMS -- 4.1.2.2 Discussion of QMS Pillars -- 4.1.2.3 Deming's 14 Points -- 4.1.2.4 Quality Management Standards -- 4.2 Cost Analysis of Quality -- 4.2.1 Categories of Quality Costs -- 4.2.1.1 Costs of Good Quality and Poor Quality -- 4.2.1.2 Direct Costs and Indirect Costs -- 4.2.1.3 Considerations in Cost Categories -- 4.2.2 Discussion on Quality Costs -- 4.2.2.1 Total Quality Cost -- 4.2.2.2 Considerations of Cost Relation -- 4.2.3 Project Economic Evaluation -- 4.2.3.1 Break‐even Estimation -- 4.2.3.2 Economic Analysis Basics -- 4.2.3.3 Economic Analysis Application -- 4.3 Quality in Production Throughput -- 4.3.1 Quality Contribution to Throughput -- 4.3.1.1 Quality in System Performance -- 4.3.1.2 Discussion on Quality Impacts -- 4.3.1.3 Quality Impacts on OEE -- 4.3.1.4 Research Example Review -- 4.3.2 Quality Analysis of Serial and Parallel Operations -- 4.3.2.1 Throughput Yield of Serial Systems -- 4.3.2.2 Quality Characteristics of Parallel Systems -- 4.3.2.3 Variation Reduction in Parallel Systems -- 4.4 Discussion of Improving Quality -- 4.4.1 Quality Appraisals -- 4.4.1.1 Product Quality Inspections -- 4.4.1.2 Layered Process Audits -- 4.4.1.3 Error‐proofing -- 4.4.2 Quality Improvement Tools -- 4.4.2.1 Qualitative Tools for Brainstorming -- 4.4.2.2 Quantitative Tools for Patterns -- 4.4.2.3 Quantitative Network Tools -- Chapter Summary -- Exercise and Review -- Exercises -- Review Questions -- References -- Chapter 5 Maintenance Management and Throughput -- 5.1 Maintenance Principles -- 5.1.1 Reliability Principles -- 5.1.1.1 Equipment Reliability -- 5.1.1.2 Failure Effect Severity -- 5.1.1.3 Failure Rate Curves.; 5.1.1.4 Failure Data Characteristics -- 5.1.2 MTBF and MTTR -- 5.1.2.1 Concept of MTBF and MTTR -- 5.1.2.2 Calculation of MTBF and MTTR -- 5.1.2.3 Relationship between λ and MTBF -- 5.1.2.4 Discussion on Failure Rate -- 5.1.3 Role of Maintenance in System Throughput -- 5.1.3.1 Maintenance in Production Management -- 5.1.3.2 General Relation to Availability -- 5.1.3.3 Quantitative Maintenance Impact -- 5.1.3.4 Quality Maintenance for Throughput -- 5.2 Equipment Maintenance Strategies -- 5.2.1 Overall Maintenance Management -- 5.2.1.1 Maintenance Planning -- 5.2.1.2 Basic Maintenance Strategies -- 5.2.1.3 TPM Approach -- 5.2.2 Reliability‐Centered Maintenance (RCM) -- 5.2.2.1 Reliability Aging Pattern -- 5.2.2.2 Process of RCM -- 5.2.2.3 Considerations for RCM Implementation -- 5.2.2.4 Fault Tree Analysis -- 5.3 Maintenance Performance Management -- 5.3.1 Key Aspects of Maintenance -- 5.3.1.1 Comparison of Maintenance Strategies -- 5.3.1.2 Maintenance for Throughput -- 5.3.1.3 Time Consideration in Maintenance -- 5.3.2 Measuring Maintenance Quality -- 5.3.2.1 Key Aspects of Maintenance Quality -- 5.3.2.2 Maintenance Performance Measurement -- 5.3.2.3 Common Maintenance KPIs -- ; 5.4 Consideration and Analysis in Maintenance -- 5.4.1 Risk and Effect Considerations -- 5.4.1.1 Risk‐based Prioritization -- 5.4.1.2 Recurrence Risk Considerations -- 5.4.2 Analysis of Maintenance Cost -- 5.4.2.1 Total Maintenance Cost -- 5.4.2.2 Maintenance Cost Justification -- 5.4.3 Additional Considerations in Maintenance -- 5.4.3.1 Impact Assessment on OEE -- 5.4.3.2 Criticality with Additional Factors -- 5.4.3.3 Maintenance Advancement -- Chapter Summary -- Exercise and Review -- Exercises -- Review Questions -- References -- Chapter 6 Throughput Enhancement Methodology -- 6.1 Approaches for Solving and Improving.; 6.1.1 Overview of Problem‐Solving and Continuous Improvement.
• Sommario/riassunto: This book, authored by Herman Tang, focuses on the analysis, improvement, and design of manufacturing system throughput. It provides a comprehensive examination of various concepts related to throughput, including performance metrics, bottleneck identification, buffer analysis, and quality management. It also delves into maintenance management and methodologies for throughput enhancement. The book is intended for professionals and students in the field of manufacturing engineering, aiming to enhance operational efficiency and effectiveness in manufacturing systems. It serves as a practical guide for implementing strategies to improve throughput and ensure system reliability.