Track: Production Planning and Management

Abstract

Performance metric is one of the components of a continuous improvement to achieve and maintain the performance of the machine or process.  Setup and changeover losses are one of the losses that increase the lead time and reduce the available time for the operation of machine. Despite of work study that used widely in industry to reduce the losses, there is no effective measurement tool to monitor the setup and changeover losses. Furthermore, excessive working time and idle time are the main focus of the people to improve, but they may miss out the other important element, the frequency of setup process in a period of time. The objective of this study is to visualize the setup losses through performance metric. Therefore, Usability and Human Factor are introduced to measure the frequency of the setup process in a period of time and highlight the excessive working time to be further streamlined. Real data was examined by using the performance metric and it showed that the performance metric able to visualize the setup losses. It is expected to visualize the setup and changeover losses in the industry and assist the user to tackle the issue correctly.