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.
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.
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.
|
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. |