System analysis of efficient production processes for productivity enhancement through productivity balance in injection moulding process

Abstract

The purpose of this paper is to present a study of mathematical model of system analysis of efficient production processes. Its objective is to perform productivity balance calculation based on data obtained from injection moulding process. Discussion on system analysis of production processes for productivity enhancement is presented. The definitions of machining time and idle time are given. The importance of coefficient of machine is also discussed. The methodology adopted in the study was to calculate the coefficient of machine of injection moulding process. The productivity balance diagram is presented to illustrate various losses associated with productivity. The productivity balance is developed based on mathematical calculation proposed and various productivity losses were identified. The improvement can be made based on these losses. An investigation was based on data obtained from injection molding machine from a company in Klang Valley. The main findings from this study include the main losses in injection moulding process can be divided among all the losses at the ratios of idle times as 0.45:11.11:0.1:0.06. These losses are QI = 0.003 parts/min, QII = 0.0562 parts/min, QIII = 0.0005 parts/min and QIV = 0.0003 parts/min. It is concluded that engineers have to create new machines with continuous processing without cyclic idle time in order to step up the automation, to solve problem in changing automatic tool, to increase the reliability of the machine, to create real automatic control of manufacturing system, to adapt automatic control of quality of parts and to determine accurate and flexible production system.