**1.1 Calculating initial installed capacity and OEE (overall equipment effectiveness)**

The initial installed capacity refers to the highest possible value given the initial standard times that are calculated. From **Table 1** it can be concluded that the bottle neck [6] is at the final lathing of the exterior with a maximum of 17 pieces an hour (bold value in **Table 1**).

**87**

material.

*The Use of Lean Manufacturing Tools to Improve the Production of Automobile Parts*

As such, the maximum installed capacity is calculated as follows:

\_ 3 turns day <sup>∗</sup>

the OEE based on an average evaluation period of 30 days per month we get:

OEE = \_\_\_\_\_\_\_\_\_\_\_ actual units

No preventive maintenance programs are in place.

**imbalance** for the different machines and operators.

of people and the flow of material in the production process.

poor distribution of the machines in the plant.

in **Table 2** and the diagram of **Figure 1**.

sity of implementing the 5S methodology.

**In order to calculate the OEE, we compare the actual capacity to the maximum possible capacity** [7]. According to the dispatch records for the second 2017 semester, the average monthly production for the plant was 3000 units. Calculating

possible units= \_

Since the OEE for the wheel hub is 31.37%, it is clear that the reasons for low

**1.2 Identification of causes that lead to low productivity in the manufacturing** 

In order to identify the leakages and causes of low productivity, the **5MQS** (methodology to identify waste related to machines, method, materials, man, management, safety and quality) [8] method was used. This was complimented with the use of an Ishikawa diagram to analyze root causes. The general find-

• **Machines:** A flow diagrams and switch travel diagrams were used as analysis tools leading to the conclusion that there is a very poor distribution within the plant. On top of that, there are constant stoppages for machine maintenance.

• **Method:** In accordance with the time studies, the critical activity (bottle

neck) is the final lathing of the exterior, meaning that productivity needs to be

• Making human-machine and machine-machine diagrams showed a **workload** 

• Constant time wasting was observed while tools and devices are sought since they are not kept in a specific place and are far away from the work station. A high level of loss is incurred due to movement of materials and people due to

• A space for raw materials is not demarcated and as such it often gets in the way

• **Checking the degree of compliance with the 5S.** Check-lists were designed for the 5S that were then used to measure compliance. The results are presented

The 55% compliance level for the 5S at the production plant indicate the neces-

• **Material:** There is a large accumulation of inventory at the bottle neck of the process, there is an imbalance in the line and lack of order for placing

\_ 25 days

3000

month = 9562.5

9562 = 0.3137

\_ pieces month

\_ hours turns ∗

*DOI: http://dx.doi.org/10.5772/intechopen.88470*

\_ pieces hour <sup>∗</sup> 7.5

17

productivity need to be found.

ings were:

**process of the M300 wheel hub**

increased at this work station [9].

*The Use of Lean Manufacturing Tools to Improve the Production of Automobile Parts DOI: http://dx.doi.org/10.5772/intechopen.88470*

As such, the maximum installed capacity is calculated as follows:

17 \_ pieces hour <sup>∗</sup> 7.5 \_ hours turns ∗ \_ 3 turns day <sup>∗</sup> \_ 25 days month = 9562.5 \_ pieces month

**In order to calculate the OEE, we compare the actual capacity to the maximum possible capacity** [7]. According to the dispatch records for the second 2017 semester, the average monthly production for the plant was 3000 units. Calculating the OEE based on an average evaluation period of 30 days per month we get:

OEE = \_\_\_\_\_\_\_\_\_\_\_ actual units possible units= \_ 3000 9562 = 0.3137

Since the OEE for the wheel hub is 31.37%, it is clear that the reasons for low productivity need to be found.
