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IND5001 Assignment 2 V1.0.1

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IND5001 Assignment 2 V1.0.1

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xz1078059196
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IND5001: Introduction to Industry 4.

0 and Applications - Assignment 2

Part 1: Process mapping and data collection

1. Find a process in your day-to-day life and simul8 it on Simul8


a. Can be any process with more than 5 steps, for example:
i. Ordering Food at Starbucks –
• Arrive, Look at Menu, Order at counter, Payment, Food
preparation, Drink preparation, Collect Order.
ii. Cooking a dish –
• Prepare ingredients, heat up pan, add condiments, cook
ingredients in order, dish up
iii. Work related production process (3D Printing) –
• Prepare 3d Model, Slice 3D model, clean build plate,
calibrate machine 0, run print, remove build, post-
processing
iv. Any other process you can find on YouTube will do as well
2. Imagine you must do this for 1 week straight for 8 hours a day excluding
weekends
3. Simulate the process in Simul8, do the following and answer the following
questions
a. Chart the process flow chart
b. Find out how many people and how much equipment is needed to ensure
a balanced production flow i.e. OEE above 75% for all steps
c. Find out how much items can you produce in this state
d. Come up with a table showing the OEE for all your steps at each stage

Step Input Output Availability Performance Quality OEE

Receiving - 10/hr 90% 93% 80% 66.96%

… … … … … … …

… … …. … … … …
Part 2: Dashboarding

Looking at the table you have made in part 1, you can see that it is a little hard to
differentiate the different statistics. In a real-world factory, there are many more items
to track in terms of production. These terms can be found in the OEE formular we have
seen before.

𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑇𝑖𝑚𝑒
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 =
𝑆𝑐ℎ𝑒𝑑𝑢𝑙𝑒𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒

𝐼𝑑𝑒𝑎𝑙 𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒 × 𝑇𝑜𝑡𝑎𝑙 𝑈𝑛𝑖𝑡𝑠 𝑃𝑟𝑜𝑑𝑢𝑐𝑒𝑑


𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 =
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑇𝑖𝑚𝑒

𝐺𝑜𝑜𝑑 𝑈𝑛𝑖𝑡𝑠 𝑃𝑟𝑜𝑑𝑢𝑐𝑒𝑑


𝑄𝑢𝑎𝑙𝑖𝑡𝑦 =
𝑇𝑜𝑡𝑎𝑙 𝑈𝑛𝑖𝑡𝑠 𝑃𝑟𝑜𝑑𝑢𝑐𝑒𝑑

𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 = 𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 × 𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 × 𝑄𝑢𝑎𝑙𝑖𝑡𝑦

From these formulars we can see what are the major factors that influence OEE and
their components:

1. Ideal Cycle Time – Takt Time, Equipment operation cycle time


2. Good Units Produced – Process Yield
3. Scheduled Production Time
4. Total Units Produced
5. Operating Time

These data can be challenging to display all at once for operators or managers to deal
with production monitoring. These data is recorded into a database and we can arrange
the data into a dashboard for easy monitoring. This is a major component of data
visualization in Production

There is many software that can be used to do Dashboarding for example, Microsoft
PowerBI, Tableu, Looker from Google Cloud, or Grafana.
Your Task for part 2 of Assignment 2 is to put yourself in the shoes of a production
manager

1. Create a dashboard designed to display the data from the following tables
that can help you monitor the production processes
2. The dashboard can be interactive or static in nature for your design
3. Dashboard does not need to be live
4. Explain the thought process of designing the table in this way

Steps Running Current Material Waste Current Expected


Status lot Used Materials Lot Run Lot Run
Number (KG) (KG) Time Time
(Hours) (Hours)
Plate Grinding Running 20005 - - 1.3 1.5

Machine 1 Running 20002 32.4 4.2 20 30


Machine 2 Running 20004 42.5 5.3 74 108
Machine 3 Stopped - - - - -
Furnace Running 19999 - - 8 10
Wirecut Running 20000 - - 3 4
Machining Stopped - - - - -
Dimension Running 19998 - - 1 3
Measurement
Tensile Running 19998 - - 0.5 1.0
Strength
Measurement
Packing Running 19997 - - 1 1

Shipping Running 19996 - - 1 2


Steps Process Down Failure Rate Units produced
time

Plate Grinding 8% 5% 1043

Machine 1 12% - 205


Machine 2 40% - 102
Machine 3 3% - 733
Furnace 4% - 1037
Wirecut 15% - 1036
Machining 20% 4% 1035
Dimension Measurement 30% 4% 1034

Tensile Strength 14% 10% 1034


Measurement
Packing 70% - 1033

Shipping 70% - 1032


Here are some examples of dashboards from past students:

1. Using Grafana

2. Using Power BI

3. Using Powerpoint
4. Using Excel and photoshop

5. Using Powerpoint

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