Driving Efficiency and Effectiveness through Production Management Systems
Production enhancement programs like Total Production Management (TPM) or Six Sigma are introduced in most production plants. These programs significantly focus on the involvement and commitment of operators to maximally mobilize existing resources within the organization.
Implementing High Performance Targets
A familiar example of reaching for the highest production levels is setting a seldom-reached level as a target for daily production. This is a clearly feasible target that triggers efforts to understand how to make it permanent. Another organizational example highlighting the role of these programs is Quick Tool Change (QTC). Overall Equipment Effectiveness (OEE) is also in line with TPM.
Achieving Effective and Efficient Production
Line equipment is dedicated to purpose, aiming for higher output at a lower reject rate to achieve the lowest cost price per meter of pipe. However, it is wise to determine the direction before pushing for higher output. If increased production leads to higher reject rates, its effectiveness may be questionable. Often, several production aspects need simultaneous modification to be effective. The core principle is to first master the process before attempting to speed up. Afterward, production can be made more efficient step-by-step through higher output, less overweight, cheaper formulations, and more automatic process controls, without sacrificing quality. Standards for the pipe application must still be met.
Technical Specifications
Metric
Description
OEE Calculation Example
0.9 (Availability) x 0.9 (Performance) x 0.9 (Quality) = 73% of max. production
Typical OEE in Seasonality
Higher than 80% is rare.
Reject Cost vs. Overweight
3% less reject saves equal to 1-2% overweight, depending on collateral costs.
FAQ Section
How do TPM and Six Sigma programs improve production output in PVC pipe manufacturing?
These programs enhance production by focusing on operator involvement and commitment to mobilize resources. They can involve setting challenging yet feasible daily targets and improving processes like Quick Tool Change (QTC) to reduce downtime, contributing to higher Overall Equipment Effectiveness (OEE).
Is simply increasing extruder size sufficient to improve OEE in PVC pipe production?
No, a bigger extruder alone is not sufficient for a higher OEE. To be truly effective, mastering the process first is crucial before increasing speed. Efficiency improvements then come from various aspects like output, overweight reduction, formulations, and controls, without compromising quality or standards.
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Humberto Goldoni
