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Master of Advanced Engineering Management
Improvement in Equipment Efficiency: Case of
Education Board Computer Centre
By
SYED MD. SHAEEDUZZAMAN
This thesis has been submitted in partial fulfillment of the requirement for the degree of
Master of Advanced Engineering Management (AEM).
Department of Industrial and Production Engineering (IPE)
Bangladesh University of Engineering and Technology (BUET),
Dhaka-1000, Bangladesh.
December 2008
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The thesis titled – “Improvement In Equipment Efficiency: Case of Education
Board Computer Centre” submitted by Syed Md. Shaeeduzzaman, Roll No.
040408116P, Session April 2004 has been accepted as satisfactory towards partial
fulfillment of the requirement for the degree of Master of Advanced Engineering
Management on November 05,2008.
BOARD OF EXAMINERS
Dr. A.K.Masud
Associate Professor
Department of Industrial and Production Engineering
Bangladesh University of Engineering and Technology
Chairman
(Supervisor)
Dr. Abdullahil Azeem
Associate Professor
Department of Industrial and Production Engineering
Bangladesh University of Engineering and Technology
Member
Dr. Nafis Ahmad
Assistant Professor
Department of Industrial and Production Engineering
Bangladesh University of Engineering and Technology
Member
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DECLARATION
It is hereby declared that this thesis paper or any part of it has not been submitted
elsewhere for the award of any degree or diploma.
Syed Md. Shaeeduzzaman
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ACKNOWLEDGEMENT
This study would not have been possible without the support and guidance of my
project supervisor Dr. A.K. M Masud, Associate Professor, Department of IPE, BUET. I
would like to take this opportunity sincerely thank him for his valuable advice, constant
support and encouragement in completing the project.
My sincerest gratitude to all the individuals of EBCC, Dhaka, who directly or
indirectly helped me out in many instance through giving their precious time for
consultancy, who are always their provide support, ideas, their constructive criticism
towards my study.
I would also like to thank my respected teachers of the department, classmates,
friends and family members who directly or indirectly gave encouragement and support
in completing my job. In addition, I would be grateful to my Division Signal and Telecom
Engineer, Bangladesh Railway, Paksey, Pabna Mr. Asim Kumar Talukder. However, my
express thanks to all person of EBCC and Railway Subordinate of office member, Paksey
because at final moment of this job I joined in Bangladesh Railway getting a better
opportunity in my service from EBCC.
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ABSTRACT
Education Board Computer Canter (EBCC), a sister concern of all Education
Board’s of Bangladesh has been done Examination related jobs; e.g., registration
processing, coding of answer scripts, publication of result, certificate and transcript
printing etc. since 1994. EBCC use Optical mark reader (OMR) to achieve these aspects
for accurate, timely, and cost-effective data collection.
This study will briefly trace the problems in data collection process in EBCC. A
detailed explanation will be made of how EBCC are able to maximize their usage of
OMR with existing system by using prevailing method Total Productive Maintenance
(TPM). Also gives a straightforward scheme for the countermeasures of data collection
process using the Pareto analysis system by means of Why Why Because Logical
Analysis (WWBLA) techniques as well as exposed the improvement of Overall
Equipment Efficiency (OEE) of the process.
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-: TABLE OF CONTENTS:-
Page
No.
Chapter-1: Overview of Education Board Computer Center
1.1 Introduction 1
1.2 Objective of the Project 2
Chapter-2: Literature Review
2.1 Introduction 4
2.2 O.M.R System in Result Processing and Student Registration 4
2.3 Methodology of the case Study 5
2.3.1 Total Productive Maintenance 6
2.3.2 Overall Equipment Efficiency 8
2.3.3 Why Why Because Logical Analysis 8
Chapter-3: Education Board’s & EBCC
3.1 Introduction 9
3.2 History of the Education Board’s 9
3.3 Structure of the Education Board’s 10
3.4 Activities of the Education Board’s 10
3.4.1 Revenue and Expenditure 11
3.4.2 Human Resources of the Education Boards 11
3.4.3 School and College Administration 11
3.4.4 Rules of Business 11
3.5 Computer System in Public Examination Process 13
3.5.1 Organization Chart of EBCC 13
3.6 Activities of Education Board Computer Center (EBCC) 14
3.7 Disbursement of Education Board in favor of Computerized Result
Processing System
15
Chapter-4: Optical Mark Reader (OMR): Scanning System
4.1 Introduction 18
4.2 AXM- 995 OMR Specifications 18
4.3 Disposition of the parts of AXM-995 OMR 20
4.4 Application of Optical Mark Reader 22
4.5 Disposition of the OMR forms used in EBCC 23
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4.6 Data Processing System in EBCC 28
4.7 Scanning System in EBCC 30
4.8 Optical Mark Reader (OMR) - Problems and Errors 33
Chapter-5: Fault Analysis: Case Study
5.1 Introduction 37
5.2 Functions of TPM 37
5.3 The Advantages of TPM 38
5.3.1 TPM - TQM (Total Quality Management) Many Similarities 40
5.4 Generalized Losses of a manufacturing organisation 40
5.4.1 Addressing the Six Big Losses 42
5.5 Importance of Overall Equipment Effectiveness 43
5.5.1 OEE Factors 44
5.5.2 Calculating OEE 48
5.6 Identification the fault process of OMR scanning system 49
5.6.1 Check Sheet 50
5.6.2 Analytical Techniques of Fault analysis 54
5.6.3 Pareto Analysis 54
5.6.4 Cause Effect and Pareto Integration 55
5.6.5 Identification the significant Losses in OMR scanning System 55
5.7 Calculating OEE for OMR 57
5.7.1 Factors influence OEE in OMR Scanning System 58
5.7.2 The Stages of WWBLA 59
5.8 Results 64
Chapter 6: Conclusion & Recommendation 66
References 68
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LIST OF TABLES
Table 1: Scanning and related picture of EBCC in S.S.C Examination 2007
Table 2 : Scanning and related picture of EBCC in H.S.C Examination 2008
Table 3 :Shorting Expenses of S.S.C Examination 2007 & H.S.C Examination (in BDT)
Table 4:Scanning Expenses of S.S.C Examination 2007 & H.S.C Examination ( in BDT)
Table 5: General Technical Information of AXM 995 OMR
Table 6: Electrical Characteristics of AXM 995 OMR
Table 7: Mechanical Characteristics of AXM 995 OMR
Table 8: Dimensions of the Machine of AXM 995 OMR
Table 9: Printer Characteristics of AXM 995 OMR
Table 10: Replacement parts list of AXM 995 OMR
Table 11: Similarities and difference between TQM and TPM
Table 12: Generalized Losses of a manufacturing organisation
Table 13: Overall Equipment Efficiency Factor
Table 14: Representation World Class OEE Factor
Table 15: Period & Phase the OMR machine stop in study period.
Table 16: Pareto Chart for Six major Losses in OMR Scanning System
Table 17: Major Causes of machine stoppages
Table 18: Why Why Because Logical Analysis (WWBLA) worksheet.
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LIST OF FIGURES
Figure 1: Organization Chart of EBCC
Figure 2: AXM-995 OMR (Front End)
Figure 3: AXM-995 OMR (Back End)
Figure 4: AXM-995 OMR (Light Barrier Sensors)
Figure 5: H-type form
Figure 6: E-type form
Figure 7: SIF-type form (top side)
Figure 8: SIF-type form (bottom side)
Figure 9: M Type OMR form
Figure 10: P Type OMR form
Figure 11: Flow chat of Data Processing system in EBCC.
Figure 12: Flowchart of scanning system
Figure 13 : A Tag sheet used in EBCC
Figure 14: Impact of maintenance on competitiveness
Figure 15: Overall Equipment Effectiveness Model
Figure 16: Check sheet use for counting the No. of Time(s) the fault Occurred
Figure 17: Check sheet use for counting the Total Stopping Time (in Min.) of the OMR.
Figure 18: Pareto Chart for six major losses
Figure 19: WWBLA Overview
Figure 20: Pareto Chart for major causes of machine stoppage
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ABBREVIATIONS
EBCC Education Board Computer Center
SSC Secondary School Certificate Examination
HSC Higher Secondary Certificate Examination
BISE Board of Intermediate & Secondary Examination
OMR Optical Mark Reader
TPM Total Productive Maintenance
OEE Overall Equipment Efficiency
GOB Government Of Bangladesh
IT Information Technology
BISE Board of Intermediate and Secondary Education
SIF Student Information Form
MCQ Multiple Choice Questions
HEX Hexa Decimal Number
TQM Total Quality Management
NG Not Go
WWBLA Why Why Because Logical Analysis
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Chapter-1: Introduction
1.1 Introduction:
Education Board Computer Center (EBCC) is the sisters concern of eight educations
boards. All these autonomous bodies are functioning under a same platform, example of
which is the simultaneous result publication. Chairman of Dhaka Education Board
governs functionalities of it as an additional appointment and Senior System Analysts are
in charge of different boards. All the boards are combined here for security purpose and
to facilitate simultaneous jobs of result processing, to exchange ideas, views and
technologies directly. It acts as a bridge among the boards [1].
The Boards of Intermediate and Secondary Education including are responsible for
conducting the public examinations such as Secondary School Certificate (S.S.C) and
Higher Secondary Certificate (H.S.C) level public examinations. The Boards’ are also
responsible for the reorganization of the private sector educational institute.
To publish the result of S.S.C. and H.S.C. Examinations more correctly and fast,
Computer Center of Bangladesh University of Engineering and Technology (BUET) was
given the responsibilities of publishing the results of two public examinations in 1994 of
then four boards (Dhaka, Rajshahi, Comilla and Jessore) with computer technology using
coding mechanism and O.M.R. (Optical Mark Reader) technology. Then in 1995
Education Board Computer Center started its operation at Dhanmondi, Dhaka with the
own work force of respective boards. Now Dhaka Board, Rajshahi Board, Chittagong
Board, Madrasah Board, Barisal Board under Jessore Board and Sylhet Board under
Comilla Board are functioning at Computer Center.
Fast result publication of S.S.C. and H.S.C. Examinations of the boards, registration
processing, preparing admit card, tabulation sheet, transcripts and certificates and other
examination related jobs are done in this center. Here the operations are performed
through computerized system with the help of O.M.R. technology. Since commencement,
it has been publishing the result before the scheduled time and publishing the result in
international standard grading system of S.S.C. Examination since 2001 and of H.S.C.
Examination since 2003.
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Education Board Computer Center (EBCC) is the largest O.M.R. mechanism based
computerized setup for public examination perhaps in Asia. At present 34 high-techs,
O.M.R. machines are operating here. Moreover, it is coping pace with the fast changing
technologies in both software and hardware. EBCC is mainly an IT (Information
Technology) organization and its main structure based on OMR machine. Therefore, in
this case study efficiency improvement of OMR machine is regarding a crucial issue.
In today's fast-paced information-driven society, the need for accurate, timely, and
cost-effective data collection is very critical. Optical mark reader (OMR) systems can be
used to achieve these aspects. This case study describes the development of a low-cost
and high-speed OMR system for marking multiple-choice questions and related
arrangement. Effective mark detection and verification algorithms have been developed
and implemented to achieve real-time performance at low computational cost.
There are some identified problems while operating the OMR machines. That is why
the production target cannot achievable every time. The problems of OMR machine are -
Sheets are not accepted, unidentified sheet, Length error, Jam before head, Jam under
head etc. Those are being the faulty input material of OMR machine [2]. Productivity is
getting down due to improper use of production management. Lake of schedule
maintenance, continuous production also hampers [3].
Total Productive Maintenance (TPM) is a maintenance program, which involves a
newly defined concept for maintaining plants and equipment. The goal of TPM is
markedly increase production, while at the same time, increasing employee morale and
job satisfaction as well as increase the efficiency of the system. TPM [4] deals with the
tools and techniques, which help identifying and reducing equipment losses to
maximizing overall equipment efficiency (OEE) [5]. This study describes the
development on how the TPM tools and techniques can be applied in EBCC for
improving efficiency (OEE) of the OMR machine.
1.2 Objective of the Project:
To implement the IT (Information Technology) in all sectors of GOB
(Government of Bangladesh), at fast GOB is executing IT policy in the Education Sector.
On this way, GOB (Government of Bangladesh) was given the responsibilities of
publishing the results of S.S.C. and H.S.C. examinations more correctly and fast to the
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computer center of Bangladesh University of Engineering and Technology (BUET). In
1995, this job is assigned to EBCC. EBCC is committed to do all the job assign by the
authority timely, accurate and cost effective way. One of the technologies in common use
at EBCC is optical mark reading (OMR). Day by day, the area of business of EBCC is
increased with the change of IT (Information Technology). In addition, the OMR usage
has increased with the system. The need has arisen for additional user services support in
the areas of OMR documentation, education, utility programming, and office procedures.
Therefore, the efficiency improvement of OMR machine is a vital topic. On this concern
of the OMR process, the objective of thesis is following:
• To identify the different fault of the OMR process.
• Root cause analysis of the process.
• Pareto Analysis of the process.
• To improve quality of the process.
• To reduce production cost by means of reducing time loss.
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Chapter 2: Literature Review
2.1 Introduction:
Education Board’s objective is to provide quality service in Secondary and Higher
Secondary level of education specially in conducting examinations and to maintain the
standard of educational institutions. For these reasons, it introduced computerized system
in result processing and registration, international standard grading system, result
publication through website and so on.
An optical mark reader has a document feed hopper and several stackers. It works
with those documents, which are printed with mark positions on its specified areas. A
mark made in a position using a dark pencil or black ink is read by OMR. The OMR can
read about 10,000 documents per hour. It is a document reader and is commonly used for
quick evaluation of Multiple Choice Examination answer sheets [1].
2.2 O.M.R System in Result Processing and Student Registration:
EBCC is used OMR form for collecting data. Data is captured from compatible
scripts by scanning through O.M.R. (Optical Mark Reader) machine. There is no scope of
inaccuracy in information gathering. The forms are machine-readable where a student has
to fill up few circles to provide personal information (viz. name, father’s name, date of
birth, school/college code etc.). These filled circles are read through O.M.R. and
information is gained which makes the database.
In this method of mark recognition, a thin beam of light is directed on the surface
of the paper, which contains dark pencil, or black ink marks. Since the dark mark absorbs
comparatively more light than the surrounding area, it reflects laser light to the detector.
This reduction in reflected light helps to recognize the mark.
Answer script contains 31-digit special code called litho-code. Moreover, the
examiners when given for evaluation cannot recognize the script that to which student or
to which school/college it belongs to. Because the portion of the O.M.R. compatible form
containing student’s roll, registration and subject code is detached from the answer script
after the exam and sent to computer center. As the examiner cannot identify the student or
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institution of the answer script, student gets justification in evaluation. After evaluation
head examiner sends the second portion of O.M.R. readable form of the answer script to
the computer center. In this system, modern and practical oriented litho-code is used
which is a random code with 31 digits and unique for every scripts. This litho-code is
matched by computer software and the mark against a roll no. is got and thus tabulation is
made based on that. In computerized system, no data is entered manually. Each
information is entered by scanning through O.M.R. machine. Therefore, there is no scope
of mistake in information gathering and result processing. Result is published correctly
and fast by the present computer system. For this reason, students get opportunity to get
admission in colleges/universities timely, which helps to reduce session jam. There is no
session jam in S.S.C. and H.S.C. level.
2.3 Methodology of the case Study:
In this study, firstly all sections of the EBCC are pointed out for assessment. It is
observed that the goal of all factory improvement activity is to increase productivity by
minimizing input and maximizing output. Output refers not only to increased productivity
but also to better quality, lower costs, timely delivery, improved industrial safety and
hygiene and to a more a favorable working environment.
At this point equipment and machinery are the crucial factors increasing output.
Productivity, quality, cost and delivery, as well as safety, hygiene, environment, and
morale are all influenced significantly by equipment conditions.
The goal of maintenance management is to enhance equipment effectiveness and
maximize equipment output. It strives to attain and maintain optimal equipment
conditions in order to event unexpected breakdowns, speed losses and quality defects in
process. Overall efficiency, including economic efficiency is achieved by minimizing the
cost of upkeep and maintaining optimal equipment conditions throughout the life of
equipment. Therefore, the steps that were followed are:
• Identification of major losses
• Identification of significant losses by Pareto analysis
• Calculation of Overall Equipment Efficiency(OEE)
• Reduction of losses with analytical Techniques.
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At first, all the sections of EBCC are studied. Then it is identified and reduced
equipment losses to maximize overall equipment efficiency (OEE) by using the tools and
techniques of Total Productive Maintenance (TPM). From the different analytical
techniques used in TPM for improvement, here we used WWBLA (Why Why Because
Logical Analysis).
2.3.1 Total Productive Maintenance:
After the Second World War the Japanese Industry realized, that they must have a
higher quality in the products to compete on the world market. The Japanese companies
were importing the management and manufacturing technologies from the USA, and then
tailored them to their needs .To be effective in the maintenance their imported the concept
of the preventive maintenance from the USA for over 40 years ago. Later were also the
principles of the productive maintenance, the maintenance prevention and the reliability
engineering imported. The company Nippondenso co. was the first to start with the
productive maintenance , 1969 they introduced TPM , to meet the challenges in growing
amount of the automation and the new demands , the automation was creating to the
maintenance and to the whole company. In 1971, the same company got the first
“Distinguished Plant Prize “, given by the JIPM, Japanese Institute of Plant Maintenance
(Nakajima, 1988). To eliminate waste, Toyota became one of the first companies to
implement TPM Nakajima, 1988). Toyota measures six categories of equipment losses
throughout its production System [4]. These are (also Fredendall 1996):
• Equipment failures: Sporadic and chronic equipment failure / breakdowns
sudden and unexpected sporadic breakdowns are infrequent and result from the
deterioration of the mechanical and electrical operating components. For
example a hydraulic error in tool changer of the CNC - machine tool or an
electrical error in the CNC - control etc. Chronic breakdowns, which are the
result of the defects in equipment, tools, materials, and operating methods, occur
frequently, resulting in small amounts of lost time. For example, unpredicted
cutting tool breakdowns in the chip- breaking of difficult materials, mistakes in
the choice of the manufacturing methods etc.
• Setup and adjustment: Make-ready and equipment adjustments. With shorter
run lengths, smaller batches and more make-readies, reduction in make- ready
time and new job adjustments, emphasis is being placed on time - to - good
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counts. For example when a new job comes to a machine tool, tooling and
fixtures have to be changed.
• Idling and minor stoppages: Material abnormalities and slight machine
malfunctions that can be overcome by replacing materials or resetting press
components. For example, incoming material has not equal quality; the
automating tool changer is not working properly.
• Reduced speed: For example while numerous reasons are advanced for running
presses and bindery equipment at slower than rated speeds , less than label -
speeded operations represent a productivity loss .
• Defects in the process: Defective products, for whatever reason
must be treated as a loss and therefore eliminated. For example, dimensions a
dimension are not inside of the tolerance area. The products have some surface
damages etc.
• Reduced yield: start up losses. Start - up loss is lost time after the make-ready is
complete and production sheets / signatures are being counted, but at a reduced
speed. The losses are generally accepted as a process variable, but
account for considerable productivity loss [3].
These six losses are combined into one measure of overall equipment effectiveness
(OEE), which is:
OEE = Equipment availability x Performance Efficiency ×Rate of Quality Products
In the year, 1995 there were are about 800 companies or company units using the TPM in
Japan Johansson, 1996). In addition, the European companies have started to apply TPM;
one of the very first has been the Swedish car manufacturer Volvo in the Gent
factory in Belgium.
In Sweden especially the IVF (Institute for verkstadsteknisk forskning) has made
big efforts to implement TPM in the Swedish companies, also in the small - and medium
Sized enterprises.
2.3.2 Overall Equipment Efficiency:
OEE (Overall Equipment Efficiency) is a "best practices" way to monitor and
improve the efficiency of any manufacturing or operating processes (i.e. machines,
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manufacturing cells, assembly lines). OEE is simple and practical. It takes the most
common and important sources of manufacturing productivity loss, places them into three
primary categories and distills them into metrics that provide an excellent gauge for
measuring where we are - and how we can improve! OEE is frequently used as a key
metric in TPM (Total Productive Maintenance) and Lean Manufacturing programs and
gives you a consistent way to measure the effectiveness of TPM and other initiatives by
providing an overall framework for measuring production efficiency [5].
2.3.3 Why Why Because Logical Analysis:
WWBLA technique is a worksheet which identities the root causes of problem
[5]. In this technique, each major problem is considered separately and a worksheet is
prepared. For each problem, a cause is identified and called it first factor for problem.
Then it is verified whether it can be divided into further root causes. If it is possible, then
it is marked as G. Here, G stands for Go. Then a second factor for problem is identified is
verified. In this way, a third, fourth problems are identified. If it is not possible to identify
further, then verification is marked as NG (Stand for No Go). Finally, countermeasures
are identified for each causes of problem [6].
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Chapter-3: Education Board’s & EBCC
3.1 Introduction:
According to the ordinance of the board, The East Pakistan Intermediate and
Secondary Education Ordinance, 1961 (East Pakistan Ordinance No. XXXIII of 1961)
and its amendments No. XVI of 1962 and No. XVII of 1977, it is responsible for the
organization, regulation, supervision, control and development of Intermediate and
Secondary level public examinations and educational institutions.
3.2 History of the Education Board’s:
The Board of Intermediate and Secondary Education (BISE), Dhaka was
established on 7 May 1921 according to the recommendation of Sadler Commission.
Intermediate colleges and high schools in Dhaka city and Islamic intermediate colleges
and high Madrasah of greater Bengal were under control of that board. An advisory board
made by the director of public education department of greater Bengal was given the
governance of that board.
Dhaka Board was dissolved in September 1947 by a government order. Its name
was changed to ‘East Bengal Secondary Education Board’ in 1955 and it was live until
1961. Scope of this new board was limited to secondary level education of then the East
province of Pakistan and control of intermediate education was shifted to the University
of Dhaka.
Responsibility of intermediate education was given to the board from the
university in 1961 and board was named ‘Board of Intermediate and Secondary
Education, East Pakistan’.
In addition, after liberation it was named ‘Board of Intermediate and Secondary
Education, Dhaka’ with the scope of operation within Dhaka division. By the rise of
population of the country and to meet with the global change, government of Bangladesh
(GOB) has given deep look on education sector. To make easy of operation of the job
Govt. day by day increase the numbers of the education boards. At present Rajshahi,
Comilla, Jessore, Chittagong, Barisal, Sylhet and Madrasah the seven other education
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boards are working on the same fundamental policy of the first education board of the
country. Very soon a new education board namely Dinajpur Education Board is going to
start its journey with the same platform.
3.3 Structure of the Education Board’s:
All Boards of Intermediate and Secondary Education (BISE) are an autonomous
body and its business functions under the supervision of Ministry of Education of GOB.
The Chairman is the Chief Executive Officer of the board. The Chairman and eleven
members of different categories comprise a board committee approved by the ministry for
three (3) years, which is responsible for smooth functioning of the board.
Moreover there are several more committees formed according to ordinance and
related rules, viz.
(1) Academic Committee,
(2) Examination Committee,
(3) Disciplinary Committee,
(4) Finance Committee,
(5) Selection Committee,
(6) Regulation Committee,
(7) Appeal and Arbitration committee,
(8) Name and Age Correction Committee and so on.
3.4 Activities of the Education Board’s:
Preparation and arrangement of registration for students of class IX and XI for
two public examinations- S.S.C. and H.S.C. and result publication of those examination
within a specific duration. After publication of result of the two examination the
education board are distributed the tabulation sheet, academic transcript and certificate
among the students via schools and colleges. Reserving the interests of teachers’ jobs
through inspection of educational institutions, investigation, appeal and arbitration and
considering the extension of job of non-government qualified teachers. Inspecting newly
established educational institutions and giving approval, renewing approval, approving
the managing committee is of schools and governing bodies of colleges and permitting
the enrollment of students according to the government rules. Examination related overall
activities; viz. question papers preparation, revision, printing of question papers through
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B.G. Press, sending the question papers to the centers timely through respective Deputy
Commissioners with secrecy, distribution of answer scripts, which include O.M.R.
(Optical Mark Reader) compatible forms among examiners after the exam, and
arrangement of payment of remuneration of related teachers.
3.4.1 Revenue and Expenditure:
The education boards are a self-depended institution. Its sources of revenue are
examination, registration, permission, approval, renewal of approval, affiliation etc. The
Government of Bangladesh (GOB) approves the annual budgets made by the boards. It
takes no financial help from the GOB.
3.4.2 Human Resources of the Education Boards:
Chairman and some other top-level posts are filled up by the senior officers of
Education Cadre on deputation. Rest of the officers and employees are the own staff of
the board, job of which is regulated by the service rule of the boards. Number of officers
and employees are fixed based on the volume of responsibilities.
3.4.3 School and College Administration:
Permission for establishment of new schools and colleges (Private) and then
academic approval are given by the boards. Moreover, approval of managing committees
of schools and colleges, disposal of their disputes, inspection and supervision are few of
its important businesses.
3.4.4 Rules of Business:
To start a new school or college, application must be submitted to the boards four
months before the commencement of academic year defined by government. Fees of the
board have to be submitted in favor of Secretary of board through C.D. of Bank of each,
B.I.S.E. or Demand Draft respective Bank. No other mode of payment is accepted.
Attempts have to be taken to form new managing committee/governing body before
expiration date of managing committee/governing body and have to be submitted to board
within the scheduled time for approval.
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a) Age of student for enrollment in class IX is at least 12 (Twelve) years. Any
student successfully completing class VIII from any approved school can enroll in class
IX.
b) Generally direct (First) enrollment in class IX is not permissible. But if
anybody can show the certification of Headmaster of the relevant school that he or she
has acquired the knowledge equivalent to class VIII, can be enrolled in class IX within
the 31st March of the academic year with the special consideration and prior permission
of the education board.
c) Age of student for appearing in the S.S.C. Examination is at least 14 (Fourteen)
years on 1st January of the year of examination.
d) Student above 18 (Eighteen) years old cannot study in class IX and student
above 19 (Nineteen) years old cannot study in class X.
e) There is no age limit for studying in Higher Secondary level and for appearing
in the Higher Secondary Examination.
f) It is possible to appear in the H.S.C. Examination as an irregular (Private)
examinee three years after passing the S.S.C. Examination.
g) If any student, passed from foreign system is willing to enroll in class XI of any
approved college of Bangladesh, has to take prior permission from the Inspector of
Colleges of the board.
h) If any student passed from foreign institute (board, university) is willing to
enroll in class XI of any approved college of Bangladesh has to apply for equivalency of
his acquired degree in the board.
i) For opening any new subject in any school/college, taking prior permission
from the concerned department of the board is necessary.
j) Correction of Errors in Registration Card and Admit Card: A student has to fill-
up the O.M.R. readable SIF (Student Information Form) correctly after being admitted
into class IX and XI. Then he has the option to correct any errors scrutinizing the printout
copy. No application for change will be accepted after delivery of registration card and
admit card.
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3.5 Computer System in Public Examination Process:
Examination related jobs; e.g. registration processing, coding of answer scripts,
publication of result, certificate and transcript printing etc. have been done through
computerized system using O.M.R. (Optical Mark Reader) technology since 1994. For
these purposes, there is a combined computer center in Dhaka for all education boards
named Education Board Computer Canter (EBCC) at Dhanmondi. Chairman of any
Education Boards assigned by the Ministry of Education of GOB is in charge of it as an
additional duty.
3.5.1 Organization Chart of EBCC:
Early we mention that EBCC is the sister concern of Education Board. Now we
see the organisation chart of EBBC by the following diagram:
Figure 1: Organization Chart of EBCC
Chairman
Sr. System Analyst
System Analyst
Programmer Programmer
Asst. Programmer
Asst. Programmer Asst. Programmer Asst. Programmer
Operator Operator Operator Operator
Main. Engr.
Asst. Main. Engr.
Scanning Operator’s
Shorting Operators
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3.6 Activities of Education Board Computer Center (EBCC):
Information is gathered through O.M.R. scanning of S.I.F. (Student Information
Form) which is filled up by student and registration card is given. Computerized system
has eradicated the registration complicacies and fake registration problem. Timely
registration card distribution is possible in this system. Computerized admit cards are
given to registration cardholder authentic students to sit for the examination. List is made
to packet center-wise questions of S.S.C. and H.S.C. Examination, printed by B.G. Press,
based on the number of students.
Litho-code containing O.M.R. compatible form is enclosed with the answer script.
It contains three portions. First portion includes examinee’s roll no., registration no.,
subject code, second portion contains evaluated marks by the examiner for that script and
the third one has the evaluated marks and it is attached to the answer script. Three
portions of the top sheet contain same litho-code.
After the examination first portion of the answer script and M.C.Q. (Multiple
Choice Questions) answer script (Only for S.S.C. Exam.) which is also O.M.R.
compatible sheet are sent to computer center directly (with armed squad) or through
registered mail. Packets containing first portions of O.M.R. compatible forms are
received board-wise, sorted center-wise in computer sections of respective boards and
data is received by scanning through O.M.R. machines.
Marks for practical tests are also gathered through scanning of O.M.R. compatible
forms. Answer scripts evaluated and scrutinized by examiners/head examiners contain
marks in the second portion of the O.M.R. readable sheet, which is sent to computer
center by the head examiner by hand. Data is gathered by scanning the sheets. The
scanned data remains scattered.
The result is published through litho-code matching of the first portion containing
roll no., reg. no., subject code and the second portion bearing obtained mark. Tabulation
sheet is given within 7 (Seven) days of result publication. Transcript is given within 1
(One) month of result publication. Original certificate is provided within two months of
result publication. List of scholarships is prepared.
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Besides the tasks mentioned above, it provides various types of information and
statistics as wanted by Ministry of Education, Directorate of Secondary and Higher
Education, BANBAIS, Education Board and different organizations.
3.7 Disbursement of Education Board in favor of Computerized Result Processing
System:
There is a fixed expense of EBCC excluding the remuneration and fixed asset cost
for the Computerized Result Processing System. Here we see the last two-job expense
detail of EBCC by the following tables[1]:
Table 1: Scanning and related picture of EBCC in S.S.C Examination 2007
Board Male
Student
Total OMR Form
Scanned Female Student
Total OMR Form Scanned
Total Script
Total Student
Dhaka 114523 4122821 107889 3884004 8006825 222412 Rajshahi 101009 3636310 93320 3359502 6995812 194328 Comilla 37023 1332828 35636 1282878 2615706 72659 Jessore 53456 1924423 47546 1711638 3636061 101002 Barisal 22712 817639 23360 840942 1658581 46072 Sylhet 13514 486511 14570 524502 1011013 28084 Chittagong
30376 1093529 28583 1028970 2122499 58958 Madrasha 55003 1980115 33654 1211544 3191659 88657
Total Examinee 7,23,514
Total Script/OMR from Scanned 2,60,46,497
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Table 2 : Scanning and related picture of EBCC in H.S.C Examination 2008
Board Male
Student Total OMR
Form Scanned Female Student
Total OMR Form Scanned
Total Script
Total Student
Dhaka 81802 1963248 71926 1726224 3689472 153728 Rajshahi 72149 1731576 62213 1493112 3224688 134362 Comilla 26445 634680 23757 570168 1204848 50202 Jessore 38183 916392 31697 760728 1677120 69880 Barisal 16223 389352 15573 373752 763104 31796 Sylhet 9653 231672 9713 233112 464784 19366 Chittagong
21697 520728 19055 457320 978048 40752 Madrasha
39288 942912 22436 538464 1481376 61724
Total Examinee 5,61,810
Total Script/OMR From Scanned 1,34,83,440
Table 3 :Shorting Expenses of S.S.C Examination 2007 & H.S.C Examination
(in BDT)
Examination
Board S.S.C H.S.C Total
Dhaka 77500 5600 83100 Rajshahi 60000 4500 64500 Comilla 37500 2500 40000
Jessore 39000 3250 42250 Barisal 27000 2025 29025 Sylhet 30000 2250 32250
Chittagong 31250 2500 33750 Madrasha 52500 4500 57000
Sub Total 354750 Sub Total 381875 Grand Total 736625
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Table 4: Scanning Expenses of S.S.C Examination 2007 & H.S.C Examination (in BDT)
Examination
Board S.S.C H.S.C Total
Dhaka 2402047 110684 2512731.6 Rajshahi 2098743 96740.6 2195484.12 Comilla 784712 36145.4 820857.24
Jessore 1090818 50313.6 1141131.96 Barisal 497574 22893.1 520467.48 Sylhet 303304 13943.5 317247.48
Chittagong 636750 29341.4 666091.08 Madrasha
957498 44441.3 1001939.04
Sub Total 8771447 Sub Total 9175950 Grand Total 17947397.00
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Chapter-4: Optical Mark Reader (OMR):
Scanning System
4.1 Introduction:
In the market several types of OMR is available. At EBCC out of thirty-four OMR
machines twenty-five nos. are the model of AXM 995 and the other nine nos. are the
model of AXIOME- 880. In this case, study in EBCC AXM -995 types OMR machine
was taken as sample machine. The AXM 995 has been designed in compliance with the
European IEC safety and electronics regulations for data processing devices and in
compliance with safety regulations applicable to terminals in office equipment
environment. The machine can be used in permanent operation at office temperature.
4.2 AXM- 995 OMR Specifications:
The following tables give the total over view of AXM -995 OMR [2]:
Table 5: General Technical Information
Operation Temperature: +10 to +35 degrees centigrade Relative Operation humidity 20% to 80% without condensation Storage Temperature -10 to +50 degrees centigrade Relative storage humidity 5% to 9 % Voltage 50/60HZ 115V/230V (±10%) Network Filter Delta EMI interference filter. Power Consumption 100VA
Table 6: Electrical Characteristics
Microprocessor 80c85 CMOS RAM Program memory 32KB for interpretative routine RAM data memory 32KB. Saving to Ram 3V (Lt-In) Motor Stepper Motor 3Nos. Interface Serial V24/RS 232C.
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Table 7: Mechanical Characteristics
Capacity of the input lift ~ 550 documents (for 90gm/m2 ) Capacity of the output trays Refused =~70 documents
Accepted= ~400 documents (for 90gm/m2 ) Speed of document transport 14 m/s or about 7200 doc. A4/h Paper weight 80 to 160 g/m2 Paper dimension 86 × 54 mm (minimum)
305 × 229 mm (maximum) Tray management Controlled by the program
Table 8: Dimensions of the Machine
Length: 715mm Width 435 mm Depth 390 mm Weight: 35 Kg.
Table 9: Printer Characteristics
Type of Head 9 needle matrix Character set Alphanumeric. Max. number of Chars. Per doc. 120 Characters. Printing Speed 40 cm per second.
Table 10: Replacement parts list:
Transport wheel 13 Separation Wheel 1 Separation rubber kit 1 Mini pitch belt 475×¼” and 390×¼ 2 Feeding belt 1 Fuse 1.6A and 3.15 A 2 Data cable DB 25 female / male 1 Adapter DB9 fem/DB 25 male 1 Ink ribbon LC9 1
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4.3 Disposition of the parts of AXM-995 OMR:
1. Selector Switch
2. Start Button
3. Sixteen Character display unit
4. Separation Button
5. Feed Tray
6. Adjuster of document width
7. Selector of document width
8.Refused Tray
9. Adjuster of false document tray.
10.Output Tray
11. Hinged Cover including the printer option
12. Selection zone of True and False document
13.Optical Reading Head
Figure 2: AXM-995 OMR (Front End)
1. Main Power Switch
2. General Fuse
3. Power Plug
4. Parallel Plug
5. Serial Connector
Figure 3: AXM-995 OMR (Back End)
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1. LB. A Controls if there are documents in the
input tray for automatic feeding
2. LB. B Detects a document before it passes under
the read head
3. LB. C Controls the document transport and
detects if the lower output tray is full. The reader
display will indicate GOOD TRAY FULL.
4. LB. D Controls the document transport and
detects if the upper ejection tray is full. The reader
display will indicate BAD TRAY FULL.
Figure 4: AXM-995 OMR (Light Barrier Sensors)
The Optical Mark Reader AXM 995 is an automatic device with a motorized
feeding tray and two output trays for the document. Its conception provided easy use and
access to documents and requires little maintenance. Its high transportation speed and the
unique feeding system make it a particularly secure and efficient device. Its programming
possibilities make it flexible, user friendly and easy to integrate into any data system.
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4.4 Application of Optical Mark Reader:
There are different types of OMR machines. Optical Mark Reading (OMR)
technology is to process larger volumes of information faster and with greater accuracy.
They eliminate the need for manual data entry and collection by processing thousands of
documents an hour, automatically. What’s more, the variety of forms our scanners can
accommodate is almost limitless. Listed above are just some of the many applications our
scanners are used for. The small footprint, lightweight yet durable design and versatility
of the OMR make it an ideal device for a wide variety of data gathering applications:
• Retail Counters: Points of sale, Workstations
• Medical applications: Doctor orders, lab reports, patient visits, health risk
appraisal
• Education: Test scoring, multiple-choice examination forms
• Game: Gaming windows, betting houses
• Lottery, survey, ballot processing, voting booths, polling centers
• Kiosks and other remote locations, when coupled with a laptop computer, etc.
• Staffing/Employment: Job Knowledge Tests, EEOC and Civil Service Tests,
Employment Applications, Drug Testing and Tests, Employee Record Keeping,
• Benefits and Compensation: Time and Attendance (Payroll) ,COBRA ,Enrollment
and Change Forms, Benefit Evaluation Forms, United Way , Tuition Assistance,
Stock Purchase/401(k) Options
• Health and Safety: Safety Training/Testing, Hazardous, OSHA Compliance,
Communication Training, Response Forms, Health Risk Appraisals
• Training and Development: Skills Assessment Forms, Certification Testing,
Opinion and Organizational, Instructor Evaluation Surveys, Course Enrollment,
Technical Training Programs, and Attendance.
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4.5 Disposition of the OMR forms used in EBCC:
1. Timing Mark
2. Page Head
3. Bullet Mark
4. Litho Codes
Figure 5: H-type form
The above OMR form is known as H-Type form in EBCC. The HEX code of 31
characters, 1 character of Board identity, 3 character of Subject code, 4 character of
Examiner Code, 4 character of answer script serial, 1 character of answer script extra paper
identity, 3 character of mark identity, 3 character of Head examiner mark identity data is to
collected from the form. The data file also given the identity of bullet mark. The bullet
mark represent from feed accurately or not.
1. Timing Mark
2. Page Head
3. Bullet Mark
4. Litho Codes
Figure 6: E-type form
The above OMR form is known as E-Type form in EBCC. The HEX code of 31
1
2
3
4
4 3
1
2
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characters, 1 character of Board identity, 1 character of Examination identity, 3 character
of Subject code, 6 character of Student Roll No., 6 characters of Student Registration No.
data is to be collected from the form. The data file also given the identity of bullet mark.
The bullet mark represent from feed accurately or not. This two from are matching by
HEX Code.
This is a double
headed form. By
this form a Student
all information for
registration of S.S.C
& H.S.C are
collected. In Name
(40 Characters) ,
Student
Examination Board
(1 Character),
Passing Year ,Roll
No.& Registration
No. (6 Characters)
respectively, and
similar data which
mention in the
figure is collected.
Figure 7: SIF-type form (top side)
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Figure 8: SIF-type form (bottom side)
This is back portion of the previous form. The mention list data are collected from
the sheet. Data accuracy also be collected by Bullet Marks. This can be feed by the OMR
machine by any way, but the programming language can be represented the data in
sequence.
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Figure 9: M Type OMR form
This form knows as M -Type OMR in EBCC. This type OMR form is widely used in
various types of recruitment examination. The form is designed based on the other forms
using the, Timing Mark, Page Head, Bullet Mark etc. In EBCC, this form is used only in
S.S.C examination.
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Figure 10: P Type OMR form
Several types of from are used in EBCC for different categories of data collection.
To design a new from and to read by machine is possible in form Timing mark & page
Head are designed in the same manner.
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4.6 Data Processing System in EBCC:
Data collection procedure and result publication procedure of Education Board’s
of Bangladesh is done by EBCC. The entire procedures are shown by the following flow
chart diagram: ---
Figure 11: Flow chat of Data Processing system in EBCC.
The operation of EBCC is started when the OMR form is going on hand to the
students. The students first fill up the forms according to their respective information. The
False Data
OMR form fill up by the student
Send the OMR form to EBCC
Shorting
Scanning the OMR forms
Humidifying the OMR forms
Making Primary Database
Solve the database
Making Secondary Database
Making Final Database
Tabulate the database
Result
Manually Checked Data
Decoding
Scanning
Sorting
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schools, colleges or examination centers authority collected the OMR forms and make the
packet. The respective authority then send these document to EBCC for taking further
action. The computer centre team then collected the all documents, which are coming to
their address from all corners of the country.
The first stage of data processing of EBCC is called shorting. In this stage
operator of EBCC is open the packet of OMR forms as well as the make a record both a
hard copy and a soft copy of the OMR forms. In the document the identity of the OMR
forms, i.e. numbers of forms with the schools, colleges or examination centers is
recorded. As the forms mainly arrival to EBCC by postal department it takes few days for
delivery. However, the forms are thin and packed a two or more thousand lots; so that
was untidy. These types of forms are making disturb while given to OMR machine for
feeding. To rectify these problems the lots of OMR forms are passing through a hot air
flow by the humidifier machine.
The third and the vital stage of data processing is the scanning. Our case study
mainly based on this stage. In this stage, the forms are feed by OMR machine. The
information of the OMR forms is recorded as text document by machine and its related
software through data cable.
The documents then converted as database information. From this data, error and
true data are marking separate. The true data are taking for further procedure. The false
data are sending to previous stage once for checking more consciously. Later the
information is repeated for previous action and after that, which was doing the further
procedure with the true data. Finally, all the data are proceeding for final action.
When the finished data is generated, the data is transferred for validation. In the
validation, stage each student all data are checked by means of all hidden codes by
software. In addition, the final data is captured as database in the format of Hexadecimal
number.
Later the data is used for preparing the tabulation. From the tabulated data, the
result is prepared. Before the result all, the data is stored in different database file in
Hexadecimal code. In addition, the respective files are keeping very in secret by
password. Only the chief executive of the respective education boards is the authority to
use the password. This stage is known as decoding in EBCC.
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4.7 Scanning System in EBCC:
Before time we mention the major task in EBCC is the scanning section. We
choose this section as our case study. The entire scanning system is shown in the
following:
Press Start Button of OMR
Sort out OMR From
Preparation for data scanning
Software Loading in OMR machine
Enter File Name
PC
OMR
Manually ADD OMR form
Data Storage in PC
Stop the Program
Start another file
Stop the Process
Switch on PC & OMR
Figure 12: Flowchart of scanning system.
Start Scanning OMR Sheet
False OMR Sheet/Machine Stop
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The entire scanning system by OMR machines shows in above figure 9. The files
are created in the from text file with an extension of (“X” “SUB” “T” “NUM”.doc). Here,
“X” first character of respective education board,
“SUB” subject code of the script,
“T” script category,
“NUM” number of the file created.
Each file contains 1000 / 1200 (One thousand / One Thousand two hundred)
sheets of data or very near to the same. A bundle has more or less five to six examination
center/ Examiners’ a single or multiple lots. Each files document are recoding in a
summarized method that is know as tag (Figure 10) in EBCC. If any queries of any
sheets are come for checking, the tag paper works as the hard copy of the data. Therefore,
tag paper is an important hardcopy document when the total data is prepared. In early
hours, we mention a bundle has more or less five to six examination center/ Examiners’ a
single or multiple lots; that is for searching a single sheet from a huge group of OMR
forms. Different logic programs use to purify the data. That is mention in next chapter 4.
The authority of center / Examiners’ mention the OMR forms information in a prescribed
format, along to the bundle. All this information is sequentially written down in tag sheets
(figure 13).
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Board of Intermediate and Secondary Education, DA/RJHI/JSR/CMA/SLY/CTG
SSC/HSC Examination, 200X
File Name : X/ ### /$/ ###
Serial No.
Centre /Head
Examiner Code
Total Sheets in the
Bundle
Ending Sheet Roll/ Serial No.
Cum. Count of the sheet
Actual Total
Repeat Counting
Reject Number
of Document
D/C
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
OMR Machine No.
Solve Date:
OMR Operator & Date: Backup Date
Figure 13 : A Tag sheet used in EBCC
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4.8 Optical Mark Reader (OMR) - Problems and Errors:
There are different problems and errors are showing while operating OMR machine.
Those errors are stopping the machine. Therefore, the machine operator should have a
deep look on the machine while it is running. On the time while error messages are
displayed ones’ should first remove errors of the machine and then again restarting the
machine. The common problems and errors are following:
• Sheets not accepted
There may be many reasons why sheets are not accepted by the OMR machine. If the
OMR forms are crumpled, in any way, the machine may give an error message and the
operator of the machine may need to restart the machine by removing the particular
problem. When sheets are not accepted by the OMR, the following error message may
shows in the display unit of AXM -995 OMR.
Bad Feeding: After three consecutive feedings of OMR sheet when the next OMR form
has still not arrived under light barrier LB B (2nd no. sensor) of the machine, the mention
error message showing in the display unit. The machine operators then replace the first
document (s) on the lift and press the start button of the OMR machine.
Jam Before head: The OMR form has reached on the light barrier LB B, but not the OMR
read head, the mention error message showing in the display unit. The machine operators
then remove the document having caused the paper jam. This document has not been read
correctly and should be put into tray of refused documents or back on the lift (input tray
of OMR) and press the start button of the OMR machine.
Jam Under head: The beginning of the OMR form has been detected by the OMR read
head, but its end has not been seen within a lap of one second of the document’s
appearance under the head, the mention error message showing in the display unit. The
machine operators then remove the document having caused the paper jam. This
document has not been read correctly and should be put into tray of refused documents or
back on the lift (input tray of OMR) and press the start button of the OMR machine.
Paper Press: While the document is not detected on the input lift in test mode, the
mention error message showing in the display unit. The machine operators then replaced
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new document on to the input tray of the machine and press the start button of the OMR
machine.
• Operating Error
There may be many reasons while OMR forms are available on the input tray of machine
but the running OMR machine is stopping. Those problems of AXM -995 OMR is
following:
Bad Tray full: The OMR machine has two trays –one called good tray and the next one is
bad tray. In the continuous form has been detected by the OMR read head, but its end has
not been seen within a lap of one second of the document’s appearance under the head,
the mention error message showing in the display unit. The machine operators then
remove the document having caused the paper jam. This document has not been read
correctly and should be put into tray of refused documents or back on the lift (input tray
of OMR) and press the start button of the OMR machine.
Good Tray full: While the machine is continuously operating but the read OMR form,
fulfill the good tray i.e. there is not enough space to accepted next document must be
ejected, the mention error message showing in the display unit. Also if the light barrier
LB C (3rd sensor) is obstructed by any means then the machine also stopping displaying
this error message. All documents of the good tray should be removed and press the start
button of the reader.
• Unidentified sheet
If a MCQ form/sheet is fed in upside down or back to front as well as the OMR form
definition does not compare with the load software of the AXM-995 then this error will
be displayed on the PC.
• Length error
There may be many grounds while OMR forms are available on the input tray of machine
but the running OMR machine is stopping. Those problems of AXM -995 OMR is
following:
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Sheet too short: The last transported OMR document in the machine is 6.25% shorter
than the reference document (usually the first document of a stack). Remove the
document having caused the error and press the start button of the reader to make the
machine restart.
Sheet too thin: The AXM-995 has a capability to read the 80 gms paper. The OMR sheet
which is now entering is more than 25% too thin. Remove the document having caused
the error and press the start button of the reader.
Sheet too thick: The OMR sheet, which is now entering, is more than 50% too thick.
Remove the document having caused the error and press the start button of the reader
Sheet too long: The last transported document is 6.25% longer than the reference
document (usually the first document of a stack).Remove the document having caused the
error and press the start button of the reader.
• Miscellaneous Error:
There are also some identified problems but those occur very few in the life period. Some
problem permanently stopping the machine and some may takes many to time to restart
the system. Those are being mentioned below:
Low Battery: The OMR motherboard battery of machine is empty and must be changed to
restarting the machine.
Bad Retention: The memory retention of the OMR is faulty; the battery could be defect.
Reload firmware and the application program of the machine to restart.
Path Not Free: Two documents are transported too closely to each other to the machine.
Remove the second document and press the start button on the reader. The removed
document has not been read.
No Black Gauging: The black reference of the synchronization (clock) mark sensor
varies. If the message returns after the reader has been switched off call on the
maintenance service.
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No Decoder: If during the READ of OMR form or in BARCODE test the barcode option
is not there or defect, the reader will display NO DECODER. Firstly installed the barcode
software and restart the machine.
Probl Bac Appel: The input tray (lift) could not move up. Make sure nothing blocks the
movements of the input tray and press the start button. If the message returns call the
maintenance service.
Good Tray Error: The tray of accepted documents could not move up. Make sure nothing
blocks the movements of the tray and press the start button. If the message reappears, call
the customer service.
Security Stop: The security of the input tray (lift) is activated. Remove the fingers or
documents from the input tray and press the start button. If the message reappears, call
the maintenance service.
No Sheet in Good: The OMR form, which should be ejected to the tray of good OMR
forms, did not arrive Look for the document in the tray of refused OMR forms. This
OMR form has been read correctly. Press the start button to start the machine.
No Sheet In Bad: The OMR form, which should be ejected to the tray of refused OMR
form, did not arrive look for the document in the tray of accepted OMR forms. Press the
start button to start the machine.
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Chapter-5: Fault Analysis: Case Study
5.1 Introduction:
Data collection and processing of the true data is the main job of EBCC. In the
case of entire processing of S.S.C / H.S.C examination result is completed by 60 (sixty)/
65 (sixty-five) working days. Total system of the result processing is already shown in
Figure 8. The entire system has dependent on four sections:
§ Sorting
§ Scanning
§ Validation
§ Decoding.
The major job of EBCC is done by scanning sections and the job is based on
OMR machine. Besides first two sections are working more or less simultaneously and
required about 45 (forty-five) to 50 (fifty) working days to complete. Moreover, the rest
two sections complete the final job within the rest stipulated time. Therefore, in case of
EBCC we use TPM for improvement the entire result processing system. We give a deep
observation on the OMR machine scanning system for better time management. In
addition, we are applying WWBLA as analytical instrument.
5.2 Functions of TPM:
A great amount of organizations finds, that in spite of the huge improvements in
the productivity in the last years, there is still a big potential to be better in utilizing the
machine tools and in reaching the better productivity goals. Like the Japanese say, “To
discover the mountain of possibilities “. One main method to meet this challenge is the
TPM. TPM is a systematic approach to understanding the equipment's function, the
equipment's relationship to product quality and the likely cause and frequency of failure
of the critical equipment components.
According to Japanese scientist Nakajima and Suzuki,” A formal definition and
concept is given by:
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1. TPM is aimed at maximizing equipment effectiveness through the optimization
of equipment availability, performances, efficiency and product quality.
2. TPM establishes a maintenance strategy (level and type of PM, productive
maintenance) for the life of the equipment.
3. TPM covers all departments such as the planning department, the users and the
maintenance department.
4. TPM involves all staff members from top management down to shop floor
workers.
5. TPM promotes improved maintenance through small group autonomous
activities.
5.3 The Advantages of TPM:
A systematic and long - term work with the TPM has an influence especially on
the following elements in any organisation
• Productivity is improving through fewer losses in the company
• Quality is also been improved as a result, that the failures and malfunctions are
reduced and the order and method are focused
• The Costs are lower, because the losses, and other not value generating work
are reduced
• The Delivery Times can be kept better, because the production without
disturbances is easier to plan
• Environment and Security is better, because leakages are tightened.
• Motivation is higher, because the responsibility and rights are delegated and
the investment in the personal is done, in the form of education.
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Total Available Time on Equipment Six Big Losses Overall Equipment
Effectiveness
Capabilities Competitive
Factors
Down Time Losses
Speed Losses
Defect Losses
Availability
Performance Efficiency
Equipment Failure
Setup and Adjustment
Idling & Minor Stoppage
Reduced Speed
Defects in Process
Reduced Yield
Rate of Quality Products
First Changeover Capability
Reduced Buffer Inventory
Increased Effective Capacity
Less Scarp and rework
Delivery
Flexibility
Cost
Quality
Decreased Lead Time
Figure 14: Impact of maintenance on competitiveness
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5.3.1 TPM - TQM (Total Quality Management) Many Similarities:
The TPM program closely resembles the popular Total Quality Management
(TQM) program. Many of the tools such as employee empowerment, benchmarking,
documentation etc. used in TQM are used to implement and optimize TPM. The final
goal is to deliver a product, which is filling all the quality requirements of the customer,
and that all the costs can be predicted. It can be said, that the maintenance and the quality
are two different features of the same issue. So, that the maintenance is long - termed
quality control. The maintenance is concentrating on the machine, processes and slow
trends; meanwhile the quality control is dealing with tools, wear - off and the
management of fast changes.
Table 11: Similarities and difference between TQM and TPM
Category TQM TPM
Objective Quality(output and effects) Equipment (input and cause)
Means of attaining
goal
Systemize the management. It is
software oriented
Employees participation and it is
hardware oriented
Target Quality for PPM Elimination of losses and wastes
5.4 Generalized Losses of a manufacturing organisation:
One of the major goals of TPM and OEE programs is to reduce and /or eliminate
the losses of what are called the Six Big Losses – the most common causes of efficiency
loss in any manufacturing or simply any organisation which have a job on similar to
production. The following table lists the six big losses, and shows how they relate to the
OEE loss categories.
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Table 12: Generalized Losses of a manufacturing organisation
Six Big Loss Category
OEE loss Category
Event Examples
Comment
Breakdowns Down time loss
Tooling failures
Unplanned maintenance
General Breakdowns
Equipment failure
There is flexibility on where to set the threshold between a breakdown (down time loss) and a small stop (speed loss).
Setup and adjustments
Down time loss
Setup/changeover
Material shortages
Operator shortages
Major adjustments
Warm-up time
This loss is often addressed through setup time reduction programs.
Small stops Speed loss Obstructed product flow
Component jams
Misfeeds
Sensor blocked
Delivery blocked
Cleaning/checking
Typically only includes stops that are under five minutes and that do not require maintenance personnel
Reduced speed Speed loss Rough running
Under nameplate capacity
under design capacity
equipment wear operator
inefficiency
Anything that keeps the process from running at its theoretical maximum speed (a.k.a. Ideal run rate or nameplate capacity).
Startup rejects Quality loss Scrap
Rework
In-process damage
In-process expiration
Incorrect assembly
Rejects during warm-up, startup or other early production. May be due to improper setup, warm-up period, etc.
Production Rejects Quality loss Scrap Rework In-process damage In-process expiration Incorrect assembly
Rejects during steady-state production.
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5.4.1 Addressing the Six Big Losses:
The six big losses are and some of the events that contribute to these losses, we can
focus on ways to monitor and correct them. Categorizing data makes loss analysis much
easier, and a key goal should be fast and efficient data collection, with data put to use
throughout the day and in real-time.
• Breakdowns:
Eliminating unplanned down time of any plant is essential to improving OEE. Other
OEE factors cannot be addressed if the process is down. It is not only important to know
how much down time your process is experiencing (and when) but also to be able to
attribute the lost time to the specific source or reason for the loss (tabulated through
reason codes). With down time and reason code data tabulated, root cause analysis is
applied starting with the most severe loss categories.
• Setup and adjustments:
Setup and adjustment time is generally measured as the time between the last good parts
produced before setup to the first consistent good parts produced after setup. This often
includes substantial adjustment and/or warm-up time in order to consistently produce
parts that meet quality standards. Tracking setup time is critical to reducing this loss,
together with an active program to reduce this time (such as an SMED - single minute
exchange of dies program). Many companies use creative methods of reducing setup
time including assembling changeover carts with all tools and supplies necessary for the
changeover in one place, pinned or marked settings so that coarse adjustments are no
longer necessary, and use of prefabricated setup gauges.
• Small stops and reduced speed:
Small stops and reduced speed are the most difficult of the six big losses to monitor and
record. Cycle time analysis should be utilized to pinpoint these loss types. In most
processes, recording data for cycle time analysis needs to be automated since cycles are
quick and repetitive events that do not leave adequate time for manual data logging. By
comparing all completed cycles to the ideal cycle time and filtering the data through a
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small stop threshold and reduced speed threshold the errant cycles can be automatically
categorized for analysis. The reason for analyzing small stops separately from reduced
speed is that the root causes are typically very different, as can be seen from the event
examples in the previous table.
• Startup rejects and production rejects:
Startup rejects and production rejects are differentiated, since often, the root causes are
different between startup and steady state production. Parts that require rework of any
kind should be considered rejects. Tracking when rejects occur during a shift and/or job
run can help pinpoint potential causes, and in many cases, patterns will be discovered.
Often a six sigma program, where a common metric is achieving a defect rate of less than
3.4 defects per million "opportunities", is used to focus attention on a goal of achieving
"near perfect" quality.
5.5 Importance of Overall Equipment Effectiveness:
Many organizations that recognize the important roll equipment and process
performance have on bottom line results are turning to the measure, which drives TPM
called Overall Equipment Effectiveness (OEE), which incorporate not only availability
but also performance Rate and Quality Rate. In other words, OEE addresses all losses
caused by the equipment: not being available when needed due to breakdowns or setup
and adjustment losses; not running at the optimum rate due to reduced speed or idling and
minor stoppage losses; and not producing first A1 quality output due to defects and
rework or start up losses. A key objective of TPM is to cost effectively maximize Overall
Equipment Effectiveness through the elimination or minimization of all losses. A simple
model outlining these losses is shown in figure 15.
When many organizations first measure OEE it is not uncommon to find they are
only achieving around 40 %-60% (batch) or 50%- 75% (continuous process) whereas the
international best practice figure is recognized to be +85% (batch) and 95% (continuous
process) for Overall Equipment Effectiveness. In effect, this means there exists in most
companies the opportunity to increase capacity/productivity by 25%-100%. TPM
significantly reduces operational and maintenance costs by focusing on the root cause of
failure through the creation of a sense of ownership by the plant & equipment operators,
maintainers and support staff to encourage “prevention at source”. To understand the
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thinking behind TPM we need to investigate what causes failure. Most of the concept of
the root cause of failure and the too used to assist in the search for the root cause
WWBLA.
5.5.1 OEE Factors:
OEE factor denotes the plant's efficiency and effectiveness as well as the overview of
productivity losses that occur in the typical manufacturing environment. Therefore, the
OEE calculation starts with plant operating time and end up at fully productive time,
showing the sources of productivity loss that occur in between the entire process. The Six
Big Losses describes the most common causes for efficiency loss usually found in
today's manufacturing environment. Six root causes of loss are presented, each directly
related to an OEE Factor. Here we have given detail concept of measuring the OEE of
any organisation.
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• Plant Operating Time:
The Plant Operating Time is the subtraction of the category of time called Planned
Shut Down to actual operating time; which includes all events that should be excluded
from efficiency analysis because there was no intention of running production (e.g.
breaks, lunch, scheduled maintenance, or periods where there is nothing to produce). The
remaining available time is your Planned Production Time.
Overall Equipment
Effectiveness
Availability
Performance Rate
Quality Rate
Break down
Setup and Adjustment
Reduce Speed
Idling and Minor Stoppage
Defects and Rework
Startup
Six Big Losses Target
Zero
Minimize
Zero
Zero
Zero
Minimize
Figure 15: Overall Equipment Effectiveness Model
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• Planned Production Time (Shut down Time):
OEE begins with Planned Production Time and scrutinizes efficiency and
productivity losses that occur, with the goal of reducing or eliminating these losses. There
are three general categories of loss to consider. Such as
i) Down Time Loss,
ii) Speed Loss and
iii) Quality Loss.
Availability takes into account Down Time Loss, which includes any Events that
stop planned production for an appreciable length of time (usually several minutes - long
enough to log as a track able Event). Examples include equipment failures, material
shortages, and changeover time. Changeover time is included in OEE analysis, since it is
a form of down time. While it may not be possible to eliminate changeover time, in most
cases it can be reduced. The remaining available time is called Operating Time.
• Operating Time (Down Time Loss):
Performance takes into account Speed Loss, which includes any factors that cause
the process to operate at less than the maximum possible speed, when running. Examples
include machine wear, substandard materials, misfeeds, and operator inefficiency. The
remaining available time is called Net Operating Time.
Net Operating Time:
Quality takes into account Quality Loss, which accounts for produced pieces that
do not meet quality standards, including pieces that require rework. The remaining time is
called Fully Productive Time. Our goal is to maximize Fully Productive Time. Here we
now give a look how the factors that contribute to OEE Losses are developed we can
quickly review the key points.
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Table 13: Overall Equipment Efficiency Factor
Loss OEE Factor
Planned Shutdown - Not part of the OEE calculation.
Down Time Loss - Availability is the ratio of Operating Time to Planned Production
Time (Operating Time is Planned Production Time less Down Time
Loss).
- Calculated as the ratio of Operating Time to Planed Production
Time.
- 100% Availability means the process has been running without any
recorded stops.
Speed Loss - Performance is the ratio of Net Operating Time to Operating Time
(Net Operating Time is Operating Time less Speed Loss).
- Calculated as the ratio of Ideal Cycle Time to Actual Cycle Time, or
alternately the ratio of Actual Run Rate to Ideal Run Rate.
- 100% Performance means the process has been consistently running
at its theoretical maximum speed.
Quality Loss - Quality is the ratio of Fully Productive Time to Net Operating Time
(Fully Productive Time is Net Operating Time less Quality Loss).
- Calculated as the ratio of Good Pieces to Total Pieces.
- 100% Quality means there have been no reject or rework pieces.
• World Class OEE:
OEE is essentially the ratio of Fully Productive Time to Planned Production Time (refer
to the OEE Factors section for graphic representation). In practice, however, OEE is
calculated as the product of its three contributing factors:
OEE = Availability x Performance x Quality
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This type of calculation makes OEE a severe test. For example, if all three contributing
factors were 90.0%, the OEE would be 72.9%. In practice, the generally accepted
excellent goals for each factor are quite different from each other, as is shown in the
table below.
Table 14: Representation World Class OEE Factor
Worldwide studies indicate that the average OEE rate in manufacturing plants is 60%.
However, a World Class OEE is considered to be 85% or better.
5.5.2 Calculating OEE:
As early, we described the OEE calculation is based on the three OEE Factors:
Availability, Performance, and Quality. Now here is given the procedure how each of
these factors is calculated.
Availability
Availability takes into account Down Time Loss, and is calculated as:
Availability = Operating Time / Planned Production Time
Performance
Performance takes into account Speed Loss, and is calculated as:
Performance = Ideal Cycle Time / (Operating Time / Total Pieces)
OEE Factor World Class
Availability 90.00%
Performance 95.00%
Quality 99.90%
Overall OEE 85.00%
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Ideal Cycle Time is the minimum cycle time that your process can be expected to
achieve in optimal circumstances. It is sometimes called Design Cycle Time, Theoretical
Cycle Time or Nameplate Capacity. Since Run Rate is the reciprocal of Cycle Time,
Performance can also be calculated as:
Performance = (Total Pieces / Operating Time) / Ideal Run Rate
Performance is capped at 100%, to ensure that if an error is made in specifying the Ideal
Cycle Time or Ideal Run Rate the effect on OEE will be limited.
Quality
Quality takes into account Quality Loss, and is calculated as:
Quality = Good Pieces / Total Pieces
And finally the OEE
OEE takes into account all three OEE Factors, and is calculated as:
OEE = Availability x Performance x Quality
5.6 Identification the fault process of OMR scanning system:
The OMR machine stops for different causes. For this reason, the data collection
time is required more. Our case study is to identification the major fault in scanning
system as well as to minimize the period of stopping OMR machines by means the
improvement of the Overall Equipment Efficiency (OEE).
Over the past 30 years, Japanese have studied and practiced what they term “Total
Quality Control” (TQC). One of the leaders in this movement has been Kaoru Ishikawa.
Ishikawa and others repeatedly point to fact that Japanese industrial workers are among
the worlds finest in their level of education and quantitative skills. Consequently, one of
the critical features of the Japanese approach to quality control is its focus on quantitative
methods on the factory floor.
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Based on his experience in Japanese industry, Ishikawa states that as much as 95
percent of quality related problems in the factory can be solved with seven fundamental
quantitative tools, also termed the seven “old” tools. Those are:
a) Cause Effect diagram
b) Stratification analysis
c) Check Sheet
d) Histogram
e) Scatter diagram
f) Pareto analysis
g) Control charts.
In this study, I took the two tools. Check Sheet and Pareto analysis to identify the major
problem of the OMR scanning system in EBCC.
5.6.1 Check Sheet:
A check sheet is a simple tools used to record and classify observed data. There
are two types of check sheets (a) Pictorial and (b) tabular. Of the two different types, we
use a pictorial check sheet that shows in figure 16 & 17. The designed of the two check
sheets based on our demand as our case fault identification according OMR machine
history. One sheet is to count the no of time the fault occurs and the other sheet is to
calculate the time to rectify the problems.
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Tag : Problem Check Sheet
Machine No. 13831 Operator Name: Md. Habibur Rahman
Date: 14/05/06 Script Type: H
Start Time: 12.15 p.m. Total Script: 1100
End Time: 12.34 p.m. Comments: Test Check
Error No. of Time(s) Occurred Total
Bad Feeding (BF) | 1
Jam Before Head (JBH) |||| |||| |||| 15
Jam Under Head (JUH)
Sheet too Thick (Stk)
Sheet too Thin (Stn) ||| 3
Sheet too long (Stl)
Good Tray Full (GF) | 1
Bad Tray Full (Btf)
Path Not Free(Pnf)
Security Stop (SS)
Lift Error (LE) | 1
Jam in Sorting (JIS)
Waiting Request (WR)
SOS test fail(SOS)
Paper Press (PP) |||| |||| |||| 14
Bad Retention (BR)
Other (OT)
Figure 16: Check sheet use for counting the No. of Time(s) the fault Occurred
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Tag : Problem Check Sheet
Machine No. Operator Name:
Date: Script Type:
Start Time: Total Script:
End Time: Comments:
Error Total Stopping Time (in Min.) Total Time
Bad Feeding (BF) 1 1
Jam Before Head (JBH) 3 3
Jam Under Head (JUH)
Sheet too Thick (Stk)
Sheet too Thin (Stn) #
Sheet too long (Stl)
Good Tray Full (GF)
Bad Tray Full (Btf)
Path Not Free(Pnf)
Security Stop (SS)
Lift Error (LE) 2 1
Jam in Sorting (JIS)
Waiting Request (WR)
SOS test fail(SOS)
Paper Press (PP) 2 2
Bad Retention (BR)
Other (OT)
# Time required less than 1(one) minute.
Figure 17: Check sheet use for counting the Total Stopping Time (in Min.) of the OMR.
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After studying all the sections of EBCC, the scanning sections were taken for the
case project purpose. Then all the scanning operators are informed about the case study
according to the TPM four steps policy. Three operators fill up the check sheet for fifteen
days in two sessions. From the check sheet, we summarized two categories of data for
our study purpose (Table 15). These figures denote the no times the OMR machines stops
during the case study period as well as represents the time the OMR machines shut down
for process operation.
Table 15: Period & Phase the OMR machine stop in study period.
Losses No. of times Shut down
( Causes of Machine Shut down ) Fault occurs period (in minute)
Bad Feeding (BF) 1486 22
Jam Before Head (JBH) 2642 27
Jam Under Head(JUH) 178 12
Sheet Too Thick(Stk) 141 2
Sheet Too Thin(Stn) 91 1
Sheet Too Long(Stl) 448 13
Good Tray Full(GF) 11 1
Bad Tray Full (Btf) 8 0
Path Not Free(PNF) 30 1
Security Stop (SS) 2 0
Lift Error(LE) 2 5
Waiting Request (WR) 2 0
SOS Fault(SOS) 0 0
Paper Press(PP)+Tag preparation +Bundle Packet 1280 100
Bad Retention(BR) 0 0
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5.6 Analytical Techniques of Fault analysis:
Every organisation sets a preventing method of failure before it makes any harm.
There are several proactive tools, technique and quality method enables the
identification and prevention of process or product errors before they occur. The
common analytical techniques used in TPM for improvement a process is following [7] :
i)WWBLA
ii) P-M analysis
iii) Why Why analysis
iv) Fault tree analysis
v) Failure Mode Effect analysis
vi)Pereto analysis
vii)SPC etc.
5.6.1 Pareto Analysis:
In nineteenth century Italy, the Italian economist Vilferdo Pareto observed that
about 80 percent of the country’s wealth was controlled by about 20 percent of the
population. This observation leads to what is now known as the Pareto Principle; it is also
known as “80”-“20” rule. Popular scientist Juran and Gary applied this concept to the
causes of quality failures. They stated that 20 percent of the causes account for 80 percent
failures. In general, the Pareto Principle, applied to quality, suggests that he majority of
the quality losses are maldistributed in such a way that a “vital few” quality defects or
problems always constitute a high percent of the overall quality losses (but not in strictly
an 80-20 relationship)
The intent of a Pareto analysis is to separate that vital few from the trivial many.
Thus, the Pareto analysis can assist us to identify the most important effects and causes
and to stratify the available data so that we can prioritize our products –process
improvement efforts. In general, we see two types of Pareto diagrams: (1) result-category
diagrams and (2) cause-category diagrams. Results diagrams focus on the classification
and relative importance of observable results (e.g., product defect categories such as
scratches, dents). Cause diagrams focus on the classification and relative importance of
detected causes (e.g., process related categories such as a dull cutting tool, a misaligned
die).
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5.6.4 Cause Effect and Pareto Integration:
Pareto analysis and Cause effect analysis are useful in all product life cycle
phases: definition, design, development, production, delivery, sales and service, usage
and disposal. They are systematic, through and based on simple logic. The Pareto
diagrams quantitative structure allows us to stratify and prioritize our information
(management by fact). The qualitative structure of the cause effect diagram allows us to
capture experience, engineering, judgment and reasonable technical speculation in our
results.
Pareto diagrams and cause effect diagrams analysis are frequently used together in
developing effective pro actions or corrective reactions since each provides different yet
necessary information to support the analysis. Typically, we use a Pareto analysis and the
resulting diagram to identify a critical problem or opportunity for quality improvement.
Then, we use the cause effect analysis and diagram to identify causes relative to the
effect.
The Pareto diagram helps determine the effect we select for the focus of CE
analysis. The cause effect diagram then displays all possible causes of a quality problem
or challenge and aids in identifying root causes. When the two diagrams are used
together, they become an instrument for documenting and communicating quality
improvement progress as well as for gaining perspectives on problem solving during the
quality improvement process.
5.6.5 Identification the significant Losses in OMR scanning System:
To identify losses and equipment efficiency of OMR scanning system in EBCC
we choose eight OMR machines for 6 days during operation. The data is representing in
Table 15 based on CE diagram. From these six (6) major losses, the most significant
losses are then identified by Pareto analysis.
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Table 16 : Pareto Chart for Six major Losses in OMR Scanning System
Major Losses
Time (minutes) %Composition Cumulative % Paper Press (PP)
120 58 58 Jam Before Head (JBH)
29 14 72 Bad Feeding (BF)
25 12 84 Jam Under Head(JUH)
14 7 91 Sheet Too Long (Stl)
14 7 98 Lift Error (LE)
5 2 100
Total 207 100
The diagram is given below:
Therefore, by Pareto chart it is seen that the most significant sources of OEE
losses are Paper Press, Jam before Head and Bad Feeding of the OMR scanning system.
Pareto Chart for six major losses
0
20 40
60 80
100 120
140
Paper Press (PP) Jam Before Head (JBH)
Bad Feeding (BF) Jam Under Head(JUH)
Sheet Too Long(Stl) Lift Error(LE)
Tim
e
0
20
40
60
80
100
120
Cu
mu
lati
ve %
Figure 18: Pareto Chart for six major losses
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5.7 Calculating OEE for OMR:
We know, OEE= Availability x Performance x Quality.
Again, Availability = Operating Time / Planned Production Time
Performance = Ideal Cycle Time / (Operating Time / Total Pieces)
Or, Performance = (Total Pieces / Operating Time) / Ideal Run Rate
Quality = Good Pieces / Total Pieces.
Here A, Running time per day =60 Minutes *7hrs=420 Minutes
B, Down time per day=30 minutes
C, Loading time per day=A-B=420-30=390 minutes
D, Stoppage losses per day=207/7=30 minutes
E, Operating time per day=C-D=390-30=360 minutes
F, Output per day = 2572 sheets
G, Rate of Quality Products=
(Processed amounts- Defect amount)/ Processed amounts*100
= (126000-5000)/126000*100=96.03%
[Defect amount =Error data/ Error Sheet]
H, Idle Cycle Time *=6 seconds =0.10 minutes
I, Actual Cycle time** =7 seconds=0.12 minutes
J, Actual Processing time^ =I*F=0.12*2572=309 minutes
K, Operating speed rate=H/I*100= (0.1/0.12)*100=83.33%
L, Net Operating rate=J/E*100=309/360*100=85.83%
M, Availability= (E/C)*100= (360/390)*100=92.30%
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N, Performance efficiency=K*L*100=0.8333*0.8583*100=71.52%
* Ideally a machine read 50 sheets per minute
** Actually a machine read 40 sheets per minute
^ Per hour per machine output sheets= (126000/7)/7=2571.43,
So, OEE=M*N*G*100
=0.9230*0.7152*0.9603*100
=63.39%.
5.7.1 Factors influence OEE in OMR Scanning System:
From the Pareto chart six major fault breakdowns it is seen that the most
significant sources of OEE losses are Paper Press, Jam before Head and Bad Feeding of
the OMR scanning system. Early we mentioned that we use WWBLA to make out the
subdivision of major causes that break off the OMR scanning system efficiency.
From the case report, it is easily recognize that Paper Press is the vital issue of
machine stopping. In the case study, it is seen that the AXM -995 OMR trays can accepts
500 sheets at a time. Due to the post phase, scanning system software in EBCC
maximum 250 nos. sheet / OMR form with four (4) slots read in one interval for few
subjects. Moreover, most of the subjects OMR form scan with 100 nos. forms with 10 or
max 15 bundles. The operator records data in tag form as well as the bundle is packing
according to direction of EBCC. The properties of OMR machine gives use an idea that
30 sheets can read by the OMR machine in a minute. In practical, we see this is idle case.
Students have not adequate knowledge about the OMR form uses, therefore, the handle
the OMR with negligence. The unsafe carrying system of the OMR from far distance of
the country, Students negligence as well as the paper quality may the dent OMR form
that causes occasionally stopping the OMR machine in the fault name Jam before Head,
Bad Feeding etc. These causes of stopping OMR scanning system can call Idling and
Minor Stoppage. However, Idling and Minor Stoppage of the scanning system is the
combination of Paper Press (Tag preparation + Bundle packing), Jam before Head, Bad
Feeding. It can be easily observed from the following Pareto analysis.
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Table 17: Major Causes of machine stoppages
Major Losses Time (minutes) %Composition Cumulative %
Tag preparation 49 35 35
Bundle packing 36 26 61
Jam Before Head 29 21 82
Bad Feeding 25 18 100
Total 139 100
From Figure 20, it is seen that the main cause of Idling and minor stoppage is Tag
preparation, Bundle packing, Jam before Head, Bad Feeding. Now WWBLA technique is
used for identifying the counter measures to reduce the problems.
5.7.2 The Stages of WWBLA:
Early we mention that in this study we used WWBLA techniques to identify the
root cause and then segment the root cause to solve the problem. A Why Why Because
Logical Analysis (WWBLA) starts with gathering information about the incident (Figure
15). This information is then used to construct either a List of Facts (facts listed alone) or a
Why Why-Because Logical List. When the first factor is identified then it is marked as G.
Here G means ‘Go”. The facts then divided into second factor for problem is identified
and verified. In this way, a third, fourth problems are identified. And so on. When the
factors are not segment to any factor, then it is marked as NG (stands for No Go). Finally,
countermeasures are identified for each root cause or facts of problem.
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The entire process of WWBLA is factored into eight sub processes, Such that:
i) Gather Information (Root cause identification)
ii) Determine the Facts ( Segmentation of the root cause)
iii) Create a List of Facts ( create a list of related cause/problem of the process)
iv) Create a Why Because Logical List
v) Create an Auxiliary List of Facts
vi) Determine the Mishap / Top Node
vii) Determine the Necessary Causal Factors
viii) Quality Assurance and Correction of the WB Graph (Countermeasures
identified).
The total system can be represented by the following flow chart:
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Incident occurred
Gather Information (GI)
Determine Facts (DI)
Clear picture of Course of events /
Participants?
Use list of facts
Create WWBLA
Correct WB-Graph
Determine Mishap / Top node (DM)
Assure Quality (AQ)
Create Auxiliary List of Facts (CA)
Create list of Facts (CL)
Finished
Create report
Determine Necessary casual factors
Figure 19: WWBLA Overview
Yes
No
No
Yes
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In this study, we use check sheet to get information from the history of the OMR
scanning system in EBCC. As well as we used Pareto analysis to identified the major
losses in the total process. Here we used WWBLA to find out the segmentation the main
cause and to go its last stage for find the countermeasures. Here, each fault, which
interrupts the process, is known as facts and its division is known as Auxiliary facts. The
division of those facts is to identify the mishap and to set finalized countermeasures. Each
fact and consequently the auxiliary facts are verified whether it can be divided into
further root causes. If it is possible, then it is marked as G. Here, G stands for Go. Then a
second factor for problem is identified is verified. In this way, a third, fourth problems
are identified. If it is not possible to identify further, then verification is marked as NG
(Stand for No Go). Finally, countermeasures are identified for each causes of problem.
Pareto Chart for major causes of machine stoppage
0
10
20
30
40
50
60
Tag preparation Bundle packing Jam Before Head Bad Feeding
Figure 20: Pareto Chart for major causes of machine stoppage
Cu
mu
lati
ve
%
0
20
40
60
80
100
120
Tim
e
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Table 18: Why Why Because Logical Analysis (WWBLA) worksheet.
Pro
ble
m
1st
Fac
tor
for
pro
ble
m
Ver
ific
atio
n
2nd
Fac
tor
for
Pro
ble
m
Ver
ific
atio
n
3rd
Fac
tor
for
pro
ble
m
Ver
ific
atio
n
Cou
nte
rmea
sure
s
1. Machine input tray is empty
G 1.1 Machine Operator is Busy
G 1.1.1 Operator is preparing Tag
NG 1.1.1. Tag should make from raw data using software.
2. OMR machine is wait for paper
G 2.1 OMR form is not placed accurately in the machine input tray.
G 2.1.1 Last OMR form is twisted / folding.
NG 2.1.1 Placed New OMR form / Smooth the twisted form and again placed the form.
3. OMR machine cannot take the form
G 3.1 Sheet thickness is not accurate
G 3.1.1 Two or more sheet is going to be feed
NG 3.1.1 Smooth the sheet or shuffling the sheets before placed in the machine input tray.
4. Machine is tried to take form but failed.
G 4.1 Adjust the Head of machine
G 4.1.1 Machine yet not takes the form.
G 4.1.2 Change the Transport wheel
NG. 4.1.2 Change the Separation wheel.
Pap
er P
ress
5. OMR form quality is poor
NG 5. Better quality of form should be used.
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5.8 Results:
From the WWBLA worksheet, we found five segmentations against the paper
press fault in the OMR scanning System. Due to countermeasures found in the WWBLA,
the stoppage loss per day reduced to 30 minute to 26 minutes and consequently per
machine OMR form reading capacity almost increases from 2572 sheets to 3000 sheets
in an hour. According to the equation of OEE it is seen that if the countermeasures are
taken the losses per day can be reduced and hence OEE is increased which is shown
below:
OEE= Availability x Performance x Quality.
Again, Availability = Operating Time / Planned Production Time
Performance = Ideal Cycle Time / (Operating Time / Total Pieces)
Or, Performance = (Total Pieces / Operating Time) / Ideal Run Rate
Quality = Good Pieces / Total Pieces.
Here A, Running time per day =60 Minutes *7hrs=420 Minutes
B, Down time per day=20 minutes
C, Loading time per day=A-B=420-20=400 minutes
D, Stoppage losses per day=180/7=26 minutes
E, Operating time per day=C-D=400-26=374 minutes
F, Output per day = 3000 sheets
G, Rate of Quality Products=
(Processed amounts- Defect amount)/ Processed amounts*100
= (142000-4500)/142000*100=96.83%
[Defect amount =Error data/ Error Sheet]
H, Idle Cycle Time *=6 seconds =0.10 minutes
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I, Actual Cycle time** =7 seconds=0.12 minutes
J, Actual Processing time^ =I*F=0.12*3000=360 minutes
K, Operating speed rate=H/I*100= (0.1/0.12)*100=83.33%
L, Net Operating rate=J/E*100=360/374*100=96.18%
M, Availability= (E/C)*100= (374/400)*100=93.57%
N, Performance efficiency=K*L*100=0.8333*0.9618*100=80.15%
^ Per hour per machine output sheets= (141850/7)/6=3000,
So, OEE=M*N*G*100
=0.9357*0.8015*0.9683*100
=72.62%.
Prior to apply WWBLA techniques we get OEE 63.39 %.
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Chapter 6: Conclusion & Recommendation
In the project work, it scrutinize that the two significant causes of losses that
decreases the efficiency of OMR machine, which Paper Press and Jam before head / Bad
are feeding. Of theses losses, the most significant loss Paper Press is considered for
reducing and thereby maximizing equipment efficiency. By WWBLA techniques, we
found five sections of the problems. We choose better OMR form, designed a sort
program against tag writing and used new separation and transport wheel, during the case
session. On this way, the OMR represent 9.23 % more efficient. Improve the OMR
machines OEE can improve as high as 85% or even more which is standard for Japanese
industries, if the entire root causes of significant losses are reducing.
EBCC may not think this matter earlier times i.e. because they have a loose
schedule time during this study period. However, this year GOB takes a policy to publish
the result of S.S.C and H.S.C examination within 60 (sixty) days. In this year to meet, the
schedule EBCC uses the machine more time. However, if they take the report as their
drug we are hopeful they can complete their job in the normal office time.
From the study, it is found that the concept of TPM can be applied to any industry
successfully. Today, with competition in industry at all time high, TPM may be one of the
tools that stand between success and total failure for some companies. It has been proven
a program that works. It can be adapted to work not only in industrial plants, but also in
construction, building maintenance, transportation and in variety of other situations like
EBCC. Employees must be educated and convinced that TPM is not just another
“program of the month” and that management is totally committed to the program and the
extended period necessary for full implementation. If everyone involve in a TPM
program does his or her part, and unusually high rate of return compare to resources
invested may be expected.
In the case study, it has been found that OEE has increased 72.62% from 63.39%
while a single problem was consider and analyzed by only one tool of TPM (WWBLA).
Here, it can also be mentioned that only one cause of the mentioned single problem has
been considered. Thus from the research work it can be concluded that the OEE could be
increased as high as to 85 %( which is a Japanese Bench Mark) if we consider all the
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problems and solve those by several analytical tools of TPM. Therefore, overall
performance of OMR machine can be improved by implementing TPM to EBCC for
meeting more jobs in a sort period in future.
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REFERENCES 1. (www.education board .gov. bd.) on 8.10.2007
2. Scantron Corporation, 1361 Valencia Avenue Tustin CA 92680, USA, User manual
AXM 995 OMR, April 1995.
3. Richard B. Chase, F. Robert Jacobs, Nicholas J. Aquilano, Operation Management
For Competitive Advantage, Tata McGraw-Hill Publishing Company Ltd, New
Delhi, 10th Edition 2004.
4. Venkatesh J, (www. plant –maintenance.com) An introduction to Total Productive
maintenance (TPM), The palnt Maintenance Resource Centre, Oct, 2005. Japan
Institute for Plant Maintenance, on 4.4.2007
5. (www.wem.nu/oee.html) OEE: Overall Equipment Efficiency, OEE index &
Calculation.
6. A practical Guide to Why Because Logical Analysis Method, Thilo Paul- Stuve,
September 21, 2005.
7. Creation of quality- Fundamental Strategic and Tactical Quality Tools, AIT,
Thailand.
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