Abstract
The initial adoption phase of new production technologies is the period between the first production run or technology reconfiguration and the achievement of a stable target output. This time frame is generally characterized by productivity unsteadiness, quality performance variability, and unexpected machine failures together with increasing production volumes due to the process setup and instability, which inevitably affects production output. In this context, human performance represents an additional source of variability and process instability that is dependent on the workers’ productivity, learning curve and related training activities. Hence, to effectively assess the ramp-up phase of new production technologies, an appropriate evaluation of human performance is required. This paper proposes a comprehensive framework and criteria to perform a consistent assessment of the initial adoption phase of new production technologies by introducing two OEE measurement methodologies that distinguish between human performance, process configuration and technical features of the production technology. The proposed framework is then applied to and validated by a case study concerning the introduction of a semi-automatic packaging machine in a primary multinational company in the logistics industry. This case study shows the difference between the two OEE measures, along with the values interpretation and useful insights for achieving a stable production output.
Highlights
The ramp-up is defined as the period between the end of product development and full capacity production [1]
This paper proposes a comprehensive framework and criteria to perform a consistent assessment of the initial adoption phase of new production technologies by introducing two overall equipment effectiveness (OEE) measurement methodologies that distinguish between human performance, process configuration and technical features of the production technology
Note that only the data trends for a period of 20 days are shown for confidentiality purposes, and no absolute values are reported and described
Summary
The ramp-up is defined as the period between the end of product development and full capacity production [1] Following this definition, the ramp-up phase can be more precisely defined as the process of bringing a production system up to its required operational characteristics after it has been designed and built and before it is taken into full operation [2]. The ramp-up phase can be more precisely defined as the process of bringing a production system up to its required operational characteristics after it has been designed and built and before it is taken into full operation [2] In this phase, the production process is often not fully understood and subject to errors, requiring adjustments that are costly for the company and which could lead to delays in introducing the product to the market [2]. Decisions concerning the planning and organization of the ramp-up become essentially complicated [4]
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