Line No 7 vs Line No 11:

i.

Cycle Time

Avg Cycle Time

12:00 10:48 09:36 08:24 07:12 06:00 04:48 03:36 02:24 01:12 00:00 10:30

Line No 7 11

Avg Cycle time (HR:MIN) 10:30 6:52

06:52

Line No 7

Line NO 11

Analysis of 30 Batches on both Line No7 and Line 11 showed that the average cycle time for one batch on Line no 7 is 4 Hrs higher than Line no 11. To identify this difference we further went into identifying in which areas Line No 7 is taking more time than Line No 11. Below graphs compare the Average Defects, First Pass Yield and OEE on Line no 7 and Line No 11

ii.

Defects:

Avg Defects
300 250 200 150 100 50 0 7 11 263 218

Line No 7 11

Avg Defects per batch 263 218

The No of defects on both lines is very consistent thus defects cannot be accounted for the time difference for processing more defects.

iii.

First Pass Yield:

Avg First Pass Yield

120.93 100.93 80.93 60.93 40.93 20.93 0.93 No 7 No 11 91.00 97.00

Line No 7 11

Avg First pass Yield 91% 97%

The Avg first pass yield on line no 7 and Line no 11 shows a difference of approximately 2200 tubes which results in a loss of 25min of production time. This time does not include the time lost due to micro stoppages.

iv.

OEE:

OEE in %
70% 60% 50% 40% 30% 20% 10% 0% 7 11 40% 58%

Line No

OEE in % 7 40% 11 58%

Overall Equipment efficiency shows of difference of 18% while the Target OEE is 65% which is not met by both the lines however line no7 shows significant variation from the target value. Further drilling down into the reasons for Low OEE on line no7 the next check was for equipment Downtime on both the lines.