Optimization of process parameter involved in the effectiveness evaluation of continuous line manufacturing system (CLMS)

To sustain in the global competitive market, the manufacturing organizations are adopting tools like Total Productive Maintenance (TPM), Lean Manufacturing (LM), etc. Implementation of these tools was assessed by an effectiveness index called Overall Equipment Effectiveness (OEE) Throughput Effectiveness (TE). Overall Manufacturing Line Effectiveness (OMLE) used as the performance evaluation index for the integrated tool {[}Total Productive Lean Manufacturing --TPLM{]} implementation performance has been assessed. OMLE is a robust metric of manufacturing performance that incorporates the measures like Line Availability (LA), Line Production Quality Performance (LPQP) of the product line. OMLE offers a means of controlling the whole production process by analyzing results from the totality of events with or without inventory between the processes in the product line. In the present paper, the attempt made towards identifying the bottleneck parameter (Losses in the processes --category A, the Cycle time in the processes-category B, Inventory between the process -- category C) in the bottleneck processes of the n number of the processes product line through programming (software in C). Also, the top three parameters of the processes in the n process product line have been obtained easily towards executing improvements by the engineers and managers. Analyze it with the change of inventory and zero inventory between the five, seven, and nine different processes product line processes. The suggested improvement activities (obtained from the OMLE evaluation and optimization program) are validated in south India's real case study organization and improved the bottleneck processes and losses in the product line.