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You are the manufacturing engineer at Autoworks. The car manufacturer goes through different processes, including a stamping process for sheet metal parts. The stamping press
You are the manufacturing engineer at Autoworks. The car manufacturer goes through different processes, including a stamping process for sheet metal parts. The stamping press is producing below its expected capability. The stamping press is semi-automatic, since the operator must manually locate the sheet metal blank. Some blanks are misaligned, which results in defective car panels. Defective car panels also result from problems with the stamping press (e.g., wrinkling and tearing of the sheet). You have been asked to improve the capability of the stamping process. As initial metrics for the improvement effort, you have decided to calculate the overall equipment effectiveness (OEE) the mean time between failure (MBTF) for the stamping process machine. You collected the following information: The stamping process operates two 8-hour shifts/day. Each shift, the operation is shut down for 30 minutes for breaks and for 30 minutes for a shift meeting. In addition, there are typically 30 minutes of unplanned downtime each day due to problems with the stamping press. When the stamping press was purchased, the theoretical cycle time was specified as 0.02 hours/unit . The current average daily production rate is 600 units/day. Losses in output are due to problems with the machine, requiring minor maintenance and adjustment. Out of the daily production of 600 units, approximately 50 units are rejected due to operator error in aligning the blank correctly and 10 units are rejected due to sheet damage from stamping press errors. 1) What is the OEE for the stamping process? Show the following intermediate calculations for credit: Availability, Performance Efficiency, and Quality. Show all work and include units in all calculations. (20 points) 2) What is the MBTF? Show the following intermediate calculations for credit: Total Running Time and Number of Failures. Show all work and include units in all calculations (8 points)
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