opportunity & possibility analysis
TRANSCRIPT
1
OPPORTUNITY &
POSSIBILITY ANALYSIS
Improvement on Capacity & Reduce Downtime
2
AGENDA
KVI & KPI
COST REDUCTION
UTILISATION, CAPACITY & YIELD
EVALUATION
3
KVI & KPI
KVI = Key Volume Indicator
KPI = Key Performance Indicator
INPUT OUTPUTPROCESS
KPI
KVI KVI
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COST REDUCTION
Volume
Resource
COST REDUCTION
1. Same Volume, resource reduce
5
COST REDUCTIONCOST REDUCTION
2. Increase Volume, same resource
Volume
Resource
6
COST REDUCTIONCOST REDUCTION
3. Combination
Volume
Resource
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UTILISATION, CAPACITY &
YIELD
Utilization
Running Timex 100%
Available Time
Downtime influence
The utilization
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CAUSE OF DOWNTIME
Order. ------ PPIC
Stock. ------ Raw Material
Breakdown. ---- Electric/Mechanic/Instrument
Preventive Maintenance.
Tooling / Change Over. ----- Set-up
Quality.
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UTILISATION, CAPACITY &
YIELD
Capacity
Output
Running Time
Machine setting &
Continuity
Influence capacity
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UTILISATION, CAPACITY &
YIELD
Yield
Outputx 100%
Input
Quality of Raw Material &
Continuous Process
Influence Yield
11
EVALUATIONS
EXAMPLE:
BASE OF CAPACITY/RUNNING TIME = 100 KG/HOUR
BASE OF DOWNTIME = 8 HOURS / WEEK
ACTUAL CONDITIONS:
ACTUAL CAPACITY / RUNNING TIME = 150 KG/HOUR
ACTUAL DOWNTIME = 0 HOUR / WEEK
1 Week = 168 Hours
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GENERAL FORMULA
BASE
1 WEEK = 7 * 24 HOURS = 168 HOURS
DOWNTIME 8 HOURS BECOME = 168 – 8 = 160 HOURS
PRODUCE ONLY = 160 * 100 KG/HR = 16,000 KG OIL
CURRENT CONDITION
1 WEEK = 7 * 24 HOURS = 168 HOURS
DOWNTIME 0 HOURS BECOME = 168 – 0 = 168 HOURS
PRODUCE = 168 * 150 KG/HR = 25,200 KG OIL
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SIMPLE DIAGRAM
160 168
Base
Capacity
100 Kg/hour
Actual
Capacity
150 Kg/hour
CAPACITY
TIME
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METHOD 1
FREEZE THE DOWNTIME
(1 WEEK = 7*24 = 168 HOURS), suppose to work
168 – 8 = 160 hoursSAVINGS OF OIL:
1. CAPACITY ------ (168 – 8) * (150 – 100)
160 * 50 = 8,000 Kg
2. DOWNTIME ------- (8 – 0) * 150
8 * 150 = 1,200 Kg
TOTAL = 8,000 + 1,200 = 9,200 Kg.
Base Run time * improve cap
Improved d/t * act. cap
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DIAGRAM METHOD 1
160 168
Base
Capacity
100 Kg/hour
Actual
Capacity
150 Kg/hour
CAPACITY
A
B
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METHOD 2
FREEZE THE CAPACITY
(1 WEEK = 7*24 = 168 HOURS)
SAVINGS OF OIL:
1. CAPACITY ------ 168 * (150 – 100)
168 * 50 = 8,400 Kg
2. DOWNTIME ------- (8 – 0) * 100
8 * 100 = 800 Kg
TOTAL = 8,400 + 800 = 9,200 Kg
Actual Run time * improve cap
Improved d/t * base cap
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DIAGRAM METHOD 2
160 168
Base
Capacity
100 Kg/hour
Actual
Capacity
150 Kg/hour
CAPACITY
A
B