Assembly Line Organization 17% Startup Loss - SMED (LCD TVs)

[cansezen]

Hello;

I'm working as TPM / Production Engineer and focusing on loss types in manufacturing. We've got 11 assembly lines and 2 shifts producing LCD Tv's. When we analyze the production amounts hour by hour, we clearly see that there is %17 startup loss in the mornings.

What may be the causes?

How can we accelerate assembly line organization when workers just start working in first hour in the morning?

 

[wmarhel]

Hi cansezen;

What may be the causes?

Without more information, a lot more information, all you should expect is some thought provoking ideas on potential sources of loss. I'll list some possible candidates that I would look into to either verify or eliminate as a cause:

1) People not at their stations when the shift starts. This becomes especially problematic if those who are late to start are actually at the start of the process.

2) Equipment not at an operating temperature that is suitable for the process. Easy to work around this by having one person come in "X" minutes/hours earlier to turn the equipment on if it is identified as a cause.

3) If the assembly line or work cell is "dry" when the shift starts, in other words, the assembly line is void of any work-in-process as no work is carried over the previous day. I've seen this a lot in environments where workers are paid on a piece-rate basis.

How can we accelerate assembly line organization when workers just start working in first hour in the morning?

This is a perfect example of where "go-see" is applicable. Be there prior to the shift and see what is actually going on and consider my comments above.

I'd be willing to bet that the reasons are staring right at you. You probably also want to look at each of the lines individually and focus on those that are underperforming the most.

Wayne

 

[Umang Vidyarthi]

Hello;

I'm working as TPM / Production Engineer and focusing on loss types in manufacturing. We've got 11 assembly lines and 2 shifts producing LCD Tv's. When we analyze the production amounts hour by hour, we clearly see that there is %17 startup loss in the mornings.

What may be the causes?

How can we accelerate assembly line organization when workers just start working in first hour in the morning?

As Wmarhel has suggested, a lot of more data is needed to reply your querry.

Besides, I would like to know whether 17% start up loss in the mornings refer to entire morning shift (since you have used the plural 'mornings'), or you are referring to morning hour(s); again just the first hour or more? The entire mathematic changes w.r.t. your clarification.

Looking forward to more specifics.

Umang

 

[DanteCaspian]

The best people to answer such a question are those in house. Your QAM should know how to investigate and be able to teach how to investigate quality issues.
I would start by watching silently and casually-- go and see!