Productivity Increase

1. BuP/MOE | Hasan AKAR
Bracket Productivity
Increase Project
HASAN AKAR - BUP/MOE

2. BuP/MOE | Hasan AKAR 2
Multiple Machine Usage (DIR Reduction) at Bracket
Saving:
9 Operators / Day
50,0% Process Efficiency Increase
5,6% Plant Efficiency Increase
9 x Opr./Day
18 x Opr./Day
Current
Realized
• Tapping done by operator.
• %100 thickness
measurement done
manually for every 4 pieces.
• Tapping will be eliminated.
• 4 pieces will be measured
%100 at the same time
automatically.

3. BuP/MOE | Hasan AKAR 3
Current Process
Process Flow
1-Unloading the dried work pieces from
drying shafts to measurement device
(x 4 times)
2- Unloading the machined parts (4 pieces)
and hanging to drying shafts.
(x 4 times)
3- Measurement of every single part %100
4- Tapping of the brackets
Process Info:
• 4 work pieces are produced at each
cycle of the machine.
• Current Machine Time:
XXX sec/pcs
2
1
3
4
0
5
10
15
20
25
30
35
40
45
CT Operator Time Idle time
XXX
34,3
9,5
CURRENT STATUS

4. BuP/MOE | Hasan AKAR 4
Project Steps
0
10
20
30
40
50
CT Operator
Time
Idle time
XXX
26,3
17,5
1- Implementation of Tilting Rack
 Tapping operation (process 4)
eliminated.
 Operator Time decreased 9 sec.
2- Implementation of Automatic Measurement System
0
10
20
30
40
50
CT Operator
Time
Idle time
XXX
19,1
24,7
 %100 thickness measurement
will be done by the machine
automatically.
 Manuel measurement operation
(process 3) eliminated.
 Operator Time decreased 7,2
sec.

5. BuP/MOE | Hasan AKAR 5
Conclusion
 Tapping operation eliminated.
 Manuel %100 measurement eliminated, automatic
measurement implemented.
 Operator time decreased from 34,3 sec to 19,1 sec.
 Idle time of the operator increased from 9,1 sec to
24,7 sec.
Saving :
9 Operators / Day
50,0% Process Efficiency Increase
+5,6 % Plant Efficiency Increase
0
10
20
30
40
50
CT Operator
Time
Idle time
XXX
34,3
9,5
0
10
20
30
40
50
CT Operator
Time
Idle time
XXX
26,3
17,5
0
10
20
30
40
50
CT Operator
Time
Idle time
XXX
19,1
24,7
Operator Time Evolution
Current
Step
1
Step
2
Due to dramatic reduction at operator
time; 1 operator can be able to serve the
2nd machine.