Cycle time variation analysis on shop floor production line – a case study in medical device manufacturing industry

Abstract

This is a case study of cycle time of machines and production lines of a medical device manufacturing plant. Unstable cycle times leads to unreliable production operation which in turn reduces productivity. More time, energy and money is wasted in non-value added activities. Therefore this research is done to establish strategies to improve cycle production rate of target facility. Cycle time data taken was recorded and analyzed to identify patterns. As a starting point, this report survey a few past journal to investigate the history of the cycle time study, and what kind of issues are encountered and the methods of troubleshooting. From the journal review, related parameters and guidelines are presented and summarized alongside with factors affecting those parameters. Further investigation of bottlenecks revealed the causes of both CT variation and bottlenecks. Solutions are drawn up to effectively reduce cycle time variation and eliminate bottlenecks. Proposed strategies are then used to determine improved cycle times of production lines. Percentage of improvement is then calculated to determine the success rate of solution and to compare current cycle time and improved cycle time in terms of potential of development and efficiency. Based on the procured results, the production line improvement strategies have significant positive effects on production lines.