1. MACHINE PERFORMANCE
By Ir. Gan Chun Chet

2. MACHINE PERFORMANCE
• IMPROVING YOUR MACHINE PERFORMANCE
BY KNOWING IT FIRST
• KNOWING THE CAPACITY TO PLAN AHEAD

3. MACHINE PERFORMANCE : RATIOS
• UNDERSTANDING THE RATIOS
• RATIO OF PRODUCT CHANGE (To/Ts)
To = OPERATING TIME
Ts = SETUP TIME
• INDICATES THE OPERATING TIME OVER THE
SETUP TIME

4. MACHINE PERFORMANCE : RATIOS
• RATIO OF NUMBER OF SETUPS AND
PRODUCTS (Ts/Np)
Ts = NUMBERS OF SETUP
Np = NUMBER OF PRODUCTS
• INDICATES THE RATIO OF MACHINE SETUPS
AND THE NUMBER OF PRODUCT PRODUCED
BY THE MACHINE

5. MACHINE PERFORMANCE : PERFORMANCE
INDICATOR
• MACHINE PERFORMANCE = (To/Tt) * 100
PERFORMANCE OF THE MACHINE IN PERCENTAGE
(%)
• OPERATING HOURS To
To = Tt – (Ti + Tm + Ts)
MACHINE TOTAL PRODUCTION HOURS Tt
MACHINE IDLE TIME Ti
MACHINE MAINTENANCE TIME Tm
MACHINE SETUP TIME Ts

6. MACHINE PERFORMANCE : PERFORMANCE
VARIABLES
• MACHINE TOTAL PRODUCTION HOURS Tt (FIXED)
TOTAL WORKING DAYS IN HOURS
• MACHINE IDLE TIME Ti (VARIABLE)
NO PRODUCTION SCHEDULE
• MACHINE MAINTENANCE TIME Tm (VARIABLE)
DEPENDING ON THE TYPE OF MAINTENANCE WORK
• MACHINE SETUP TIME Ts (REPETITIVE)
MONITORING REQUIRED

7. MACHINE PERFORMANCE : MONITORING SETUP
TIME – STATISTIC
• STATISTICAL TECHNIQUES
• MAXIMUM SETUP TIME
THE MAXIMUM TIME OF THE SETUPS
• MINIMUM SETUP TIME
THE MINIMUM TIME OF THE SETUPS
• AVERAGE SETUP TIME
• THE AVERAGE TIME OF THE SETUPS

8. MACHINE PERFORMANCE : MONITORING SETUP
TIME – PREDICTION/FORECASTING
• PREDICTION TECHNIQUE
• CATEGORY MODE OCCURRENCE
THE LOCATION OF THE MOST FREQUENT SETUP TIME
• DEVIATION FROM ACTUAL BY MOVING AVERAGE
AVERAGE OF TWO ACTUAL PASTS CALCULATED WITH
VARYING DEVIATION
DEVIATION FROM ACTUAL BY EXPONENTIAL SMOOTHING
THE FRACTION OF ONE (1) GUESS OR PAST AND AN ACTUAL
CURRENT WITH VARING DEVIATION

9. MACHINE PERFORMANCE : MONITORING SETUP
TIME – PREDICTION/FORECASTING
• PROBABILITY OF UP OR DOWN
THE POSSIBILITIES OF EITHER AN UP, DOWN OR
UNCHANGE COUNTED TO KNOW THE PROBABILITY
• ANGLE OF INCLINATION
THE SLOPE OF EACH POINT MOVEMENT, WHETHER IS
LOCATED AT VERY HIGH ANGLE, HIGH ANGLE, LOW
ANGLE (NEGATIVE) OR A MODERATE LOW ANGLE

10. MACHINE PERFORMANCE : MONITORING SETUP
TIME – DIAGNOSE THE REPETITIVE TASKS
• TWO TIME HIGH WITHIN THE LIMITS
TWO TIMES THE SETUP TIME INCREASES WHETHER
WITHIN AN UPPER LIMIT OR LOWER LIMIT WHICH IS
A DEVIATION FROM A CHANGING MEAN TIME
• WARNING LEVEL
A PREDETERMINE SETPOINT TO WARN USER.

11. MACHINE PERFORMANCE :
PERFORMANCE CHART
Performance Chart
10200
10000
9800
9600
9400
9200
9000
8800
0 500 1000 1500
SIMULATION
Setup Time (Ts)
Operating Hours (To)
Operating Hours
(To=Tp-Ts)
Performance Chart
10000
9800
9600
9400
9200
9000
8800
0 20 40 60 80 100
Production Hours/ Setup Hours (Tp/Ts)
Operating Hours (To)
Ratio (Tp/Ts)

12. MACHINE PERFORMANCE :
PERFORMANCE CHART
Ratio
12.0
10.0
8.0
6.0
4.0
2.0
0.0
0 5 10 15
Number of Product
Setup/Product
Setup/Product 1
Setup/Product 2
Ratio
50.0
45.0
40.0
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
0 2 4 6 8 10 12
Number of Product
Operating/Product
Operating/Product 1
Operating/Product 2
SIMULATION

13. MACHINE PERFORMANCE :
PERFORMANCE CHART
Operating Product
100
80
60
40
20
0
0 5 10 15
Number of Products
Operating Time
10 Setups
20 Setups
30 Setups
• MORE SETUP, REDUCE
OPERATING TIME
• NOTE RATIO OF
PRODUCTION AND SETUP
HOURS CHART
SIMULATION

14. MACHINE PERFORMANCE :
PERFORMANCE CHART
Warning Level
15 15 15 15 15 15 15 15 15 15
14.0
18.5
11.4
10.8
18.9
11.3
15.8
3.1
15.0
12.4
20.0
18.0
16.0
14.0
12.0
10.0
8.0
6.0
4.0
2.0
0.0
0 2 4 6 8 10 12
Number of Setups
Time (Hours)
Actual Time
Warning Level
SIMULATION

15. MACHINE PERFORMANCE :
PERFORMANCE CHART
Distribution of Hours
2.3
7.6
3.4
87
100%
80%
60%
40%
20%
0%
1
Machine
Percentage (%)
Percentage of Hours Spent On
Setups (Tsn/Ttn*100)
Percentage of Hours Spent On
Maintenance Time (Tmn/Ttn*100)
Percentage Machine Left Idle
(Tin/Ttn*100)
Machine Performance (Ton/Ttn)
SIMULATION

16. MACHINE PERFORMANCE :
PERFORMANCE CHART
Upper and Lower Limits
32.8 32.8 32.8 32.8 32.8 32.8 32.8 32.8 32.8
25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0
17.3 17.3 17.3 17.3 17.3 17.3 17.3 17.3 17.3 17.3
9.7
19.2
22.9
9.6 9.6 9.6 9.6 9.6 9.6 9.6 9.6 9.6
8.5
16.6
14.5 14.2
23.3
15.7
13.4
28.8
32.1
12.3
19.8
17.4
16.5
26.4
18.1
15.0
9.6
13.7
4.7
13.4
11.5 11.8
20.1
13.2
11.7
27.8
32.8
15.2
24.0
21.5 21.0
31.1
23.1
20.5
10.6
12.9
1.8
9.2
7.4 7.3
15.4
8.2
6.2
1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
0 2 4 6 8 10 12
Number of Setup
Time
Actual Machine Setup Time
Upper Limit (Moving Average)
Low er Limit (Moving Average)
Upper Limit (Exp Smoothing)
Low er Limit (Exp Smoothing)
Category 1 /
Category 1 / / 2 /
Category 2 / / 3 /
Category 3 / / 4 /
Category 4 /
SIMULATION

17. MACHINE PERFORMANCE
• KNOW WHAT IS ACCEPTABLE
• MONITOR TO SEE WHETHER IT IS LOCATED AT
YOUR MEAN PERFORMANCE
• IDENTIFY THE IMPROVEMENT EITHER
POSSIBLE OF NOT

18. MACHINE PERFORMANCE
• STRATEGY
• MORE OPERATION TIME
• MORE SETUPS
• KNOW YOUR MEAN

19. MACHINE PERFORMANCE
• COST OF OPERATION
• LINK TO TIME (POSSIBLE?)
• EXAMPLE:
• REDUCE SETUP?
• INCREASE FLEXIBILTY?

20. MACHINE PERFORMANCE
• KNOW YOUR MACHINE PERFORMANCE
• KNOW YOUR MEAN PERFORMANCE
• KNOW THE ESTIMATED PREDICTION

21. MACHINE PERFORMANCE
• KNOW THE CAPACITY
• PLAN AHEAD

22. MACHINE PERFORMANCE
• EXCEL FILE – THE PURPOSE
• ARTICLE – PREDICTIVE TECHNIQUE