Homework/Assignment 3

(Stability – 5S TPM)

Full Name of submitter: Student ID:

Your Group number is: …6…..

Title of your Group project is: … Presentation of Chapter 6: Cellular Manufacturing ..
Group members are:
Student ID & Full name
1. VO MY UYEN – IEIEIU18169
2. TRAN NGUYEN PHUONG LINH – IEIEIU18168
3. NGUYEN TRI DUNG – IEIEIU18171
4. CHAU NGUYEN NHAT TRUONG – IEIEIU18109
5. TRAN QUANG THUC – IEIEIU15058
6. TRAN CHI BAO – IEIEIU17048
7. NGUYEN HOANG ANH TUAN – IEIEIU17071

Production cell with the following conditions

Working time: 3 shifts/day, 5 days/week
Shift hours: 6:00 – 14:00, 14:00 – 22:00, 22:00 – 6:00
Planning related stops (no production):
Breaks: 30 minutes each shift
Meetings: Every Thursday 13:30 – 14:00
Preventive maintenance: daily during shift exchange at 6:00-6:15, 14:00 – 14:15,
22:00-22:15
Production: cycle time 9 minutes/item
True outcome during one week:
Breakdowns: Mon: 6:30-10:00; Tue: 9:00 – 10:12, Wed: 20:30 -21:48; Fri: 14:30 –
17:18
There are 553 items produced of which 8 were scrap
Calculate OEE, MTBF, MTTR for that week
Note:

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Answers/Works
Calculate OEE
Total available time per week: 24* 5= 120 hours.
[ (30∗ 3)∗ 5]
Break times per week: = 7.5 hours
60
Meeting on Thursday: 0.5 hour
[ (15∗ 3)∗ 5]
Preventive Maintenance per week: = 3.75 hours.
60
Machine breakdown times this week: 8.8 hours.
Total downtime: 20.55 hours/week
Available time: 120 – 20.55= 99.45 hours
99.45
▪ Availability of equipment: x 100 = 83%
120
99.45∗60
Product available: = 663 units
9
553
▪ Performance(%) = = 83.4%
663∗100

553−8
▪ Quality(%) = = 98.55%
553

 OEE = 83%*83.4%*98.55%= 68.21%

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Calculate MTBF
Case 1: in this case, we will consider the break time here is only the breakdowns time,
which is the period of time the machine/equipment is stop working due to technical issues
only (unplanned downtime). The planned downtime will be ignored (break of employees,
meetings or preventive maintenance)
1 shift = 8h working time/day => 3 shifts = 24 hours
5 days per week
▪ Total working time = 24 * 5 = 120 hours
▪ Breakdown:
Monday: 6:30-10:00 => 3.5 hrs.
Tuesday: 9:00 – 10:12 =>1.2hrs Total breakdown time = Total downtime
Wednesday: 20:30 -21:48 =>1.3hrs = 3.5 + 1.2 + 1.3 + 2.8 = 8.8 hrs.
Friday: 14:30 – 17:18 => 2.8hrs

▪ Number of failure/breakdowns = 4

𝑇𝑜𝑡𝑎𝑙 𝑢𝑝𝑡𝑖𝑚𝑒 𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑡𝑖𝑚𝑒−𝑇𝑜𝑡𝑎𝑙 𝑑𝑜𝑤𝑛 𝑡𝑖𝑚𝑒 120−8.8

MTBF = = = = 27.8 hours
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒 4

Case 2: we consider all the break time here will include: break of employees, Meetings,
Preventive maintenance and breakdowns.
1 shift = 8h working time/day => 3 shifts = 24 hours
5 days per week
▪ Total working time = 24 * 5 = 120 hours
▪ Break 30 minutes each shift => total time break of employees = 0.5 * 3 * 5 = 7.5 hours
▪ Meetings in every Thursday: 13:30 – 14:00 => 0.5 hour
▪ Preventive Maintenance (daily in each shift) = (0.25 + 0.25 + 0.25) * 5 = 3.75 hours
6:00-6:15 => 0.25h
14:00 – 14:15 => 0.25h
22:00-22:15 => 0.25h
▪ Total breakdown time = 3.5 + 1.2 + 1.3 + 2.8 = 8.8 hours

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▪ Total downtime = 7.5 + 0.5 + 3.75 + 8.8 = 20.55 hours
𝑇𝑜𝑡𝑎𝑙 𝑢𝑝𝑡𝑖𝑚𝑒 𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑡𝑖𝑚𝑒−𝑇𝑜𝑡𝑎𝑙 𝑑𝑜𝑤𝑛 𝑡𝑖𝑚𝑒 120−20.55
MTBF = = = = 12.43125 ℎ𝑟𝑠
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒 8

Calculate MTTR
Mon: 6:30-10:00=> 3.5 hrs.
Tue: 9:00 – 10:12=>1.2hrs
Wed: 20:30 -21:48=>1.3hrs
Fri: 14:30 – 17:18=> 2.8hrs
Total Breakdown time = 3.5 + 1.2 + 1.3 + 2.8 = 8.8 hrs.
Total Breakdown time 8.8
MTTR = = = 2.2 hours
Total scarp 4