A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners

Nowadays, Lean Manufacturing (LM) is a driving method for companies in order to succeed in global competition. Reducing as well as eliminating waste in production line using equipment is the main use of LM innovations. Having an expert in LM is a good way for companies to balance and maintain in ord...

Full description

Saved in:
Bibliographic Details
Main Author: Mohd Yunos, Ahmad Syafiq
Format: Thesis
Language:English
English
Published: 2016
Subjects:
Online Access:http://eprints.utem.edu.my/id/eprint/20766/1/A%20Proposal%20Of%20OEE%20Simulation%20Decision%20Support%20Tools%20For%20Lean%20Practitioners%20-%20Ahmad%20Syafiq%20Mohd%20Yunos%20-%2024%20Pages.pdf
http://eprints.utem.edu.my/id/eprint/20766/2/A%20Proposal%20Of%20OEE%20Simulation%20Decision%20Support%20Tools%20For%20Lean%20Practitioners.pdf
Tags: Add Tag
No Tags, Be the first to tag this record!
id my-utem-ep.20766
record_format uketd_dc
institution Universiti Teknikal Malaysia Melaka
collection UTeM Repository
language English
English
topic T Technology (General)
spellingShingle T Technology (General)
Mohd Yunos, Ahmad Syafiq
A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners
description Nowadays, Lean Manufacturing (LM) is a driving method for companies in order to succeed in global competition. Reducing as well as eliminating waste in production line using equipment is the main use of LM innovations. Having an expert in LM is a good way for companies to balance and maintain in order to deliver a good value to the customers. Nevertheless, some aspects are hard for the LM practitioner to evaluate the impact of LM tools at certain desired level after deciding and implementing appropriate LM. Hence, may negatively affect the resources and time consumed as well as cost. The aim of this study is to suggest a simulation framework of LM tools for LM practitioners which are Overall Equipment Effectiveness (OEE) in simulation-based decision support tools (SDST). The architecture of OEE-SDST based on the original framework of OEE concepts by Nakajima (1988). Integrating the average cost by relating OEE efficiency is a one of the new introductions in OEE concepts. The design and development will be built on the Microsoft Visual Basic 2010. The OEE-SDST will operate as graphical user interface(GUI). The usability study of software capability criteria based on ISO/IEC 25010:2011 or ISO/IEC 9126 that consist of understandability, learnability, operability, and attractiveness. Based on the 50 respondents, about 78% are agreed with capabilities of the OEE-SDST. To conclude, OEE-SDST capable of assist the decision making for the LM practitioner.
format Thesis
qualification_name Master of Philosophy (M.Phil.)
qualification_level Master's degree
author Mohd Yunos, Ahmad Syafiq
author_facet Mohd Yunos, Ahmad Syafiq
author_sort Mohd Yunos, Ahmad Syafiq
title A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners
title_short A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners
title_full A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners
title_fullStr A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners
title_full_unstemmed A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners
title_sort proposal of oee simulation decision support tools for lean practitioners
granting_institution Universiti Teknikal Malaysia Melaka
granting_department Faculty of Manufacturing Engineering
publishDate 2016
url http://eprints.utem.edu.my/id/eprint/20766/1/A%20Proposal%20Of%20OEE%20Simulation%20Decision%20Support%20Tools%20For%20Lean%20Practitioners%20-%20Ahmad%20Syafiq%20Mohd%20Yunos%20-%2024%20Pages.pdf
http://eprints.utem.edu.my/id/eprint/20766/2/A%20Proposal%20Of%20OEE%20Simulation%20Decision%20Support%20Tools%20For%20Lean%20Practitioners.pdf
_version_ 1747834002030460928
spelling my-utem-ep.207662021-10-10T22:54:20Z A Proposal Of OEE Simulation Decision Support Tools For Lean Practitioners 2016 Mohd Yunos, Ahmad Syafiq T Technology (General) Nowadays, Lean Manufacturing (LM) is a driving method for companies in order to succeed in global competition. Reducing as well as eliminating waste in production line using equipment is the main use of LM innovations. Having an expert in LM is a good way for companies to balance and maintain in order to deliver a good value to the customers. Nevertheless, some aspects are hard for the LM practitioner to evaluate the impact of LM tools at certain desired level after deciding and implementing appropriate LM. Hence, may negatively affect the resources and time consumed as well as cost. The aim of this study is to suggest a simulation framework of LM tools for LM practitioners which are Overall Equipment Effectiveness (OEE) in simulation-based decision support tools (SDST). The architecture of OEE-SDST based on the original framework of OEE concepts by Nakajima (1988). Integrating the average cost by relating OEE efficiency is a one of the new introductions in OEE concepts. The design and development will be built on the Microsoft Visual Basic 2010. The OEE-SDST will operate as graphical user interface(GUI). The usability study of software capability criteria based on ISO/IEC 25010:2011 or ISO/IEC 9126 that consist of understandability, learnability, operability, and attractiveness. Based on the 50 respondents, about 78% are agreed with capabilities of the OEE-SDST. To conclude, OEE-SDST capable of assist the decision making for the LM practitioner. 2016 Thesis http://eprints.utem.edu.my/id/eprint/20766/ http://eprints.utem.edu.my/id/eprint/20766/1/A%20Proposal%20Of%20OEE%20Simulation%20Decision%20Support%20Tools%20For%20Lean%20Practitioners%20-%20Ahmad%20Syafiq%20Mohd%20Yunos%20-%2024%20Pages.pdf text en public http://eprints.utem.edu.my/id/eprint/20766/2/A%20Proposal%20Of%20OEE%20Simulation%20Decision%20Support%20Tools%20For%20Lean%20Practitioners.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=104947 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering 1. Abdulmalek, F. A. and Rajgopal, J., 2007. Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study. International Journal of Production Economics, 107(1), pp.223–236. 2. Al-Kilidar, H., Cox, K. and Kitchenham, B., 2005, November. The use and usefulness of the ISO/IEC 9126 quality standard. In Empirical Software Engineering, 2005. 2005 International Symposium on (pp. 7-pp). IEEE. 3. Ahmed, T., Ali, S. M., and Allama, M. M., 2010. A Total Productive Maintenance (TPM) Approach to Improve Production Efficiency and Development of Loss Structure in a Pharmaceutical Industry, 10(2), 186–190. 4. Ali, T. A., Allama, M. M., and Parvez, M. S., 2010. A Total Productive Maintenance (TPM) Approach to Improve Production Efficiency and Development of Loss Structure in a Pharmaceutical Industry. Global Journal of Management and Business Research, 10(2). 5. Andersson, R., Eriksson, H. and Torstensson, H., 2006. Similarities and differences between TQM, six sigma and lean. The TQM Magazine, 18(3), pp.282–296. 6. Apreutesei, M., Suciu, E. and Arvinte, I.R., 2010. Lean Manufacturing - A Powerfull Tool for Reducing Waste during the Processes. Management, (2), pp.23–34. 7. Art of Lean, 2013. Toyota Production System Basic Handbook. , pp.1–32. Available at: www.artoflean.com [Accessed on 15 July 2015]. 8. Aulakh, S.S. and Gill, J.S., 2008. Lean Manufacturing-a Practitioner’s Perspective. Proceedings of the 2008 IEEE IEEM, pp.1184–1188. 9. Barletta, I., Andersson, J., Johansson, B., May, G., and Taisch, M., 2014. Assessing a proposal for an energy-based overall equipment effectiveness indicator through discrete event simulation. In Simulation Conference (WSC), 2014 Winter (pp. 1096-1107). IEEE. 10. Bednár, R., Vidová, H., and Beluský, M., 2012. Lean principles application in business logistics. In 21st International Conference on Metallurgy and Materials, Brno. 11. Balakrishnan, A., Kalakota, R., Si, Ow, P., Whinston, A.B., 1995. Document-centered information systems to support reactive problem-solving in manufacturing. International Journal of Production Economics 38, 31–58 12. Bevan, N., 2000. ISO and Industry Standards for User Centred Design. Ppt, (October). Available at: http://www.usabilitynet.org/trump/documents/Usability%20standards.ppt [Accessed on 13 August 2015] 13. BMA Incorporation, 2005. Five Principles of Lean Thinking. (May), pp.44–47. Available at: http://www.maskell.com/lean_accounting/images/FIVE%20LEAN%20PRINCIPLES.pdf [Accessed on 9 July 2015] 14. Borris, S., 2006. Total Productive Maintenance: Proven Strategies and Techniques to Keep Equipment Running at Maximum Efficiency 15. Bosch Rexroth Corporation, 2009. Lean Manufacturing : Principles, Tools and Methods Introduction : The 9 Principles of Lean Manufacturing. Methods. Available at: http://www.livhaven.com/pdf/Lean_Manufactuting_Guidebook.pdf [Accessed on 18 July 2015]. 16. Crute, V., Ward, Y., Brown, S. and Graves, A., 2003. Implementing Lean in aerospace - challenging the assumptions and understanding the challenges. Technovation, vol. 23, no. 12, pp. 917-928. 17. Czabke, J., Hansen, E.N. and Doolen, T.L., 2008. A multisite field study of lean thinking in US and German secondary wood products manufacturers. Forest Products Journal, vol. 58, no. 9, pp. 77-85. 18. Drew, J., McCallum, B., and Roggenhofer, S., 2004. Journey to lean: making operational change stick. Palgrave Macmillan. 19. Detty, R. B., and Yingling, J. C., 2000. Quantifying benefits of conversion to lean manufacturing with discrete event simulation: a case study. International Journal of Production Research, 38(2), 429-445. 20. Environment Protection Authority, 2009. Under the Environment Protection Act 1993. South Australia. Version: 1.7.2015. Available at: https://www.legislation.sa.gov.au/lz/c/r/environment%20protection%20regulations%202009/current/2009.227.un.pdf [Accessed on 2 December 2015] 21. Feld, W. M., 2000. Lean manufacturing: tools, techniques, and how to use them. CRC Press. 22. Fowler, J. W., and Rose, O., 2004. Grand challenges in modeling and simulation of complex manufacturing systems. Simulation, 80(9), 469-476. 23. Gopalakrishnan, M., Skoogh, A., and Laroque, C., 2013. Simulation-based planning of maintenance activities in the automotive industry. In Proceedings of the 2013 Winter Simulation Conference: Simulation: Making Decisions in a Complex World (pp. 2610-2621). IEEE Press. 24. Gupta, Y. P. and Gupta, M. C. A., 1989. A system dynamics model for a multi-stage multi-line dual-card JIT-Kanban system International Journal of Production Research Vol. 27, No. 2. pp 309 - 352. 25. Harris, A., 2007. Automotive special report-Made in the USA-Uprooting the Toyota Production System and transplanting it to Kentucky in the United States has proved to be a great success for Toyota. Manufacturing Engineer, 86(1), 14-19. 26. Heilala, J., Montonen, J., Järvinen P., and Kivikunnas, S., 2010. Decision Support Using Simulation for Customer-Driven Manufacturing System Design and Operations Planning. Book Chapter in Decision Support Systems, Advances in. edited by: Ger Devlin. ISBN: 978-953-307-069-8. 27. Hines, P., Holwe, M. and Rich, N., 2004, Learning to evolve - A review of contemporary lean thinking. International Journal of Operations and Production Management, vol. 24, no. 9-10, pp. 994-1011. 28. Hoornweg, D., and Bhada-Tata, P., 2012. What a waste: a global review of solid waste management. Available at: https://www.wdronline.worldbank.org/handle/10986/17388 [Accessed on 11 July 2015] 29. Jeffrey O., 2013. Overall equipment effectiveness. Control Engineering, 55(1), p.64. Available at: http://www.maintenanceassistant.com/blog/advanced-cmms-metrics-overall-equipment-effectiveness [Accessed on 12vAugust 2015]. 30. Jerry K., 2003. Lean Principles, Utah Manufacturing Extension Partnership. Available at:https://yourcareeracademy.com/yca/assets/uploads/lib_file/Lean%20Principles%20-%20overview.pdf [Accessed on 18 July 2015]. 31. Karim, S., 2009. The Impact of Just-in-Time Production Practices on Organizational Performance in the Garments and Textiles Industries in Bangladesh, Doctoral Thesis, Dhaka University. 32. Keller, L., C.Harrell, J.Leavy, 1991. The three reasons why simulation fails. In: Industrial Engineering, Volume 23, Issue 4, p27-31. 33. Kesaraju, V. S., and Ciarallo, F. W., 2012. Integrated simulation combining process-driven and event-driven models. Journal of Simulation, 6(1), 9-20. 34. Kovacheva, A. V., 2010. Challenges in lean implementation: Successful transformation towards lean enterprise. University of Aarhus, Denmark. Available at: http://pure.au.dk/portal-asb-student/files/9093/ak83188.pdf [Accessed on 11 July 2015] 35. Lehner, P.E. and Zirk, D.A.,1987. Cognitive factors in user/expert-system interaction. Human Factors: The Journal of the Human Factors and Ergonomics Society, 29(1), pp.97-109. 36. Matloff, N., 2008. Introduction to discrete-event simulation and the simpy language. Davis, CA. Dept of Computer Science. University of California at Davis. ReCALL, (98765), pp.1–9. 37. Marakas, G.M.,2003. Decision Support Systems in the 21st Century, Prentice-Hall of India Private Limited, New Delhi. 38. McLachlin, R., 1997. Management initiatives and just-in-time manufacturing. Journal of Operations Management, 15(4), 271-292. 39. Mohamad, E. Bin, Ito, T. and Yuniawan, D., 2013. A simulation-based approach to decision support for lean practitioners. 20th ISPE International Conference on Concurrent Engineering, CE 2013 - Proceedings, (LM), pp.274–283. 40. Monden, Y., 1998. Toyota Production System: An Integrated Approach to Just-In-Time (3rd ed.). Norcross, Georgia: Engineering and Management Press. 41. Mefford, R.N., 2009. Increasing productivity in global firms: The CEO challenge. Journal of International Management. vol. 15, no. 3. pp. 262-272. 42. Motwani, J., 2003. A business process change framework for examining lean manufacturing: a case study. Industrial Management and Data Systems. vol. 103, no. 5-6. pp. 339-346. 43. Nahmias, S., 2001. Production and Operations Analysis (4th ed.). New York: McGraw-Hill. 44. Nakajima, S., 1988. Introduction to TPM: Total Productive Maintenance. Cambridge, MA: Productivity Press. 45. Ng, K. C., Lim, C. P., Chong, K. E., and Goh, G. G. G.,2013. Elimination of waste through value Add/Non value add process analysis to improve cost productivity in manufacturing—A case study. In Industrial Engineering and Engineering Management (IEEM), 2013 IEEE International Conference on (pp. 410-414). IEEE. 46. Panizzolo, R., 1998. Applying the lessons learned from 27 lean manufacturers. The relevance of relationships management. International Journal of Production Economics, vol. 55, no. 3, pp. 223-240. 47. Pavnaskar,S.J.,Gershenson,J.K. and Jambekar,A.B.,2003. Classification scheme for lean manufacturing tools. International Journal of Production Research, 41(13), pp.3075-3090. 48. Pegden, C.D., 2009. Now Bring Simulation In-house to Support Good Decision Making. Available at: www.simio.biz [Accessed on 14 July 2015]. 49. Piazza, J. R., Scott, G. C., Sekutowski, J. C., and Williams, G., 1992. A systems engineering methodology for manufacturing waste minimization. AT and T Technical Journal, 71(2), 11-18. 50. Pius A., Esam S., Rajkumar R. and Geoff N., 2006. Critical success factors for lean implementation within SMEs. Journal of Manufacturing Technology Management. vol. 17, no. 4, pp. 460-471. 51. Raman, S., 1998. Lean software development: is it feasible? 17th DASC. AIAA/IEEE/SAE. Digital Avionics Systems Conference. Proceedings (Cat. No.98CH36267)1. 52. Rahman, 1998. Kos dan Anggaran sesuatu reka bentuk - Dewan Bahasa Dan Pustaka, Kuala Lumpur, pages 15-26. 53. Raigopal, J., 2004. Principles and applications of operations research. Zandin, K. Maynard’s Industrial Engineering handbook. McGraw-Hill, New York. 1677-1694 54. Rex M. G., n.d. What’s missing in Overall Equipment Effectiveness?. Availabe at:http://www.reliableplant.com/Read/28827/overall-equipment-effectiveness[Accesing on 1 September 2015]. 55. Roth, B.M. and Mullen, J.D., 2002. Decision making: Its logic and practice. Rowman and Littlefield. 56. Safe Drinking Water Foundation, 2009. Industrial Waste. Safe Drinking Water Foundation, pp.1–4. Available at:http://www.safewater.org/PDFS/knowthefacts/IndustrialWaste.pdf [Accesed on 2 July 2015] 57. Scott, D.,2014. Evaluating the National Outcomes: Youth—Social Competencies; Decision Making. Available at : http://ag.arizona.edu/sfcs/cyfernet/nowg/sc_decision.html [Accessing on 25 December 2015] 58. Selin, E., 2013. Solid waste management and health effects - A qualitative study on awareness of risks and environmentally significant behavior in Mutomo, Kenya. 59. Sheree H., 2014. Top 10: Lean manufacturing companies in the world. Available at:http://www.manufacturingglobal.com/top10/38/Top-10:-Lean-manufacturing-companies-in-the-world [Accessed on 5 December 2015]. 60. Shirose, K., Nakajima S., 1992. TPM for Supervisors. Productivity Press. 61. Simoes, V. M. D. S., 2008. Critical Factors of Lean Implementation in Manufacturing Environments. 62. Singh, N. and Brar, J.K., 1992. Modelling and analysis of just-in-time manufacturing systems. A review International Journal of Operations and Production Management. Vol. 12, No. 2, pp 3 - 14. 63. Smith, R. L., and Roberts, S. D., 2014. Sensitivity analysis for a whole hospital system dynamics model. In Simulation Conference (WSC), 2014 Winter (pp. 1305-1316). IEEE. 64. Sohal, A., Olhager, J., O’Neill, P., and Prajogo, D., 2010. Implementation of OEE–issues and challenges. Competitive and Sustainable Manufacturing Products and Services, Milano: Poliscript, 1-8. 65. Swanepoel, K.T.,2004. Decision support system: real-time control of manufacturing processes. J ournal of Manufacturing Technology Management, Vol. 15 No. 1, pp. 68-75. 66. Taichi, O., 1988. Toyota Production System. Productivity Press, June, pp. 6, 58, 126. 67. Tangen, S., 2002. Understanding the concept of productivity. Proceedings of the 7th Asia Pacific Industrial Engineering and Management Systems Conference. (APIEMS2002).Taipei 68. Toyota, 2012. Toyota production system and what it means for business. , p.20. Available at: http://www.bt-forklifts.com/SiteCollectionDocuments/PDF files/Toyota Production System Brochure.pdf. [Accessing on 11 July 2015]. 69. Ttacks, C.Y.A., 2009. Unifying Strategies and Tactics : a Survivability Framework for Countering.Management, (March), pp.119–124.The Fast Guide to OEE. 1(630), pp.1–27. Available at:http://www.vorne.com/pdf/fast-guide-to-oee.pdf [Accessed on 12 August 2015]. 70. The Complete Guide to Simple OEE, 45246(513). Available at: http://www.exoramerica.com/docs/vw121/5A55D3F673BC774EC1257481004B6C93/$file/The+Complete+Guide+to+Simple+OEE.pdf. [Accessed on 12 August 2015] 71. Venkatesh, J., 2007. An Introduction to Total Productive Maintenance (TPM). Available at:http://www.plant-maintenance.com/articles/tpm_intro.shtml , The Plant Maintenance Resource Center, pp.1–18. [Accesing on 15 July 2015] 72. Vinodh, S. and Dinesh Kumar, C., 2012. Development of computerized decision support system for leanness assessment using multi grade fuzzy approach. Journal of Manufacturing Technology Management, 23(4), pp.503-516. 73. Vorne Industries Inc., 2010. TPM – Total Productive Maintenance. Available at: http://www.leanproduction.com/tpm.html [Accesing on 10 July 2015] 74. Wang, S. and Koch, D.,2008. A Hands-on Kanban Simulation Kit for Lean Manufacturing. Proceedings of the 2008 IAJC-IJME International Conference – ISBN 978-1-60643-379-9, paper 119. 75. Watts, C. A., Hahn, C. K. and Sohn, B-K., 1994. Monitoring the performance of a reorder point system. A control chart approach. International Journal of Operations and Production Management. Vol. 14, No 2. pp 51 - 61. 76. West, A. A., Rahimifard, S., Harrison, R., and Williams, D. J., 2000. The development of a visual interactive simulation of packaging flow lines. International Journal of Production Research, 38(18), 4717-4741. 77. Womack, James P.; Daniel T. Jones; Daniel Roos., 1990. The Machine That Changed the World. Simon and Schuster. 78. Womack, J. P., and Jones, D. T., 2010. Lean thinking: banish waste and create wealth in your corporation. Simon and Schuster. 79. Wudhikarn, R., 2013. A Framework for Integrating Overall Equipment Effectiveness with Analytic Network Process Method. International Journal of Innovation, Management and Technology. Available at: http://www.ijimt.org/index.php?m=content&c=index&a=show&catid=45&id=700. [Accesing on 20 August 2015] 80. Yuniawan, D.,2014. Simulation Modeling and Analysis for Productivity Improvement in the Production Line The University of Tokushima, (March).