Operational Performance Of Automotive Parts Assembly Processes Using Production Capacity Loss Equation

• Main Author: Abdul Rasib, Amir Hamzah
• Format: Thesis
• Language: English; English
• Published: UTeM 2016
• Subjects: T Technology (General); TS Manufactures
• Online Access: http://eprints.utem.edu.my/id/eprint/18562/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=101741; HF5351.M34 2016

Hidden Time Loss (HTL) occurs along the production processes that have a significant effect on productivity in the automotive industry. Currently, Overall Equipment Efficiency (OEE) is the most popular performance measurement tool used in the production line. In this regard, availability, performance, and quality are the parameters used in OEE. However, OEE is not really fit for measuring operation performance of the manual assembly process and the semi-auto assembly process. There would be a certain amount of HTL occurring along the manual assembly process and semi-auto assembly process. HTL becomes critical when an assembly process involves a high product variety in the same production line. The aim of this research is to provide a measure for HTL through the determination of Time Loss Measures (TLM) components known as: (i) Non-valued Changeover Time (NVCOT), (ii) Inefficient Processing Time (IPT), (iii) Unnecessary Overtime (UOT), and (iv) Non-conformance Time (NCT). A Framework of TLM had been developed through a thorough literature study on manufacturing operations. Then, an equation for Production Capacity Loss (PCL) was derived based on the structure of TLM components. Finally, the structure of TLM components and the PCL equation were validated by using case study at five automotive manufacturing companies in Malaysia. The results of the case study show that HTL did occur through the four TLM components that caused an amount of PCL. In economic view, PCL can be converted into Gross Profit Loss (GPL). A significant finding from this research is the effect of TLM components on HTL in the context of different assembly features: (i) Right and Left, (ii) Product Variety, (iii) Model Variety, and (iv) Front and Rear. HTL does exist in the manual assembly process and semi-auto assembly process, especially in the automotive industry. The results show that UOT contributes as the highest HTL from the aspects of Right and Left, Model Variety, and Front and Rear; and NCT contributes the highest HTL from the aspect of Product Variety. In conclusion, PCL can be used as a measuring tool for the manufacturing companies to monitor continuously the operational performance of the manual assembly process and semi-auto assembly process.