Increase output by improving oee in an automative component production line a case of bosch vietnam

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING CAPSTONE PROJECT INDUSTRIAL MANAGEMENT INCREASE OUTPUT BY IMPROVING OEE IN AN AUTOMATIVE COMPONENT PRODUCTION LINE: A CASE OF BOSCH VIETNAM LECTURER: NGUYEN THI ANH TUYET, PhD STUDENT : HA THI NGOC ANH SKL010203 Ho Chi Minh City, 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING THESIS INCREASE OUTPUT BY IMPROVING OEE IN AN AUTOMATIVE COMPONENT PRODUCTION LINE: A CASE OF BOSCH VIETNAM HA THI NGOC ANH Student ID: 19124002 Major: INDUSTRIAL MANAGEMENT Advisor: NGUYEN THI ANH TUYET, PhD HO CHI MINH CITY, 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING THESIS INCREASE OUTPUT BY IMPROVING OEE IN AN AUTOMATIVE COMPONENT PRODUCTION LINE: A CASE OF BOSCH VIETNAM HA THI NGOC ANH Student ID: 19124002 Major: INDUSTRIAL MANAGEMENT Advisor: NGUYEN THI ANH TUYET, PhD HO CHI MINH CITY, 2023 COMMENTS OF ADVISOR HCMC, May 4, 2023 Advisor i COMMENTS OF REVIEWER HCMC, May 4, 2023 Reviewer ii ACKNOWLEDGEMENTS First and foremost, I am grateful for the help and assistance from the Faculty of High Quality, along with the guidance from my advisor Mrs Nguyen Thi Anh Tuyet Working with such a caring and professional individual like you has been my honor I would like to express my sincere gratitude toward my parents and friends for your unconditional support during my journey at HCMC University of Technology and Education I would not have made it this far without your kind words and hours of everyone effort Finally, I want to express great sincerity to the people at BOSCH – my internship company for allowing me to learn so much and meet a lot of great seniors Thanks to MSE1 and my Buddy for letting me participate in so many projects that help enrich my knowledge and skill in a professional environment HCMC, May 4, 2023 Student name Ha Thi Ngoc Anh iii LIST OF ABBREVIATION Abbreviation DMAIC FGD FMEA Explanation Define – Measure – Analyse – Improve – Control Focus group discussion Failure Mode and Effects Analysis FTA Failure tree analysis HMI Human-Machine Interface LPC Limited Production Certification OEE Overall Equipment Effectiveness POT Plant operating time TPM Total productive maintenance VOC Voice of customer WI Work Instruction WIP Work in process iv LIST OF TABLES Table Related research works 25 Table OEE and Cycle time of each process 36 Table The OEE breakdown in January 2023 41 Table Downtime by Availability loss activities in January 43 Table Quality scrap goods in January 46 Table 4 Solution for Step Control Sensor issues 49 Table Solution for Tool safety issues 51 Table Solution for Oil leakage issues 52 Table Solution for Damage Ejector issues 57 Table Status of Action plan by 10.Mar.2023 59 Table Process Control Plan 64 v LIST OF FIGURES Figure 1 Bosch’s logo Figure Pushbelt Figure Element Figure Organization chart Figure DMAIC process 13 Figure 2 PDCA Cycle 22 Figure Flowchart of thesis methodology 28 Figure PDCA cycle Gantt chart 29 Figure Bosch customer demand 34 Figure MSE1 Customer’s demand vs Capacity chart 35 Figure 3 Process flow to produce the element 36 Figure Cycle time & OEE index in every process 37 Figure Fine Blanking process 39 Figure Phases of tool inside machine 39 Figure Fine blanking machine 40 Figure 4 Target setting for each factor 41 Figure Quality (%) in January 42 Figure Availability (%) in January 42 Figure Availability’s loss Pareto chart 47 Figure Human-Machine Interface 48 Figure Failure tree analysis for Step Control Sensor issues 48 Figure 10 Fine blanking tool 49 Figure 11 Failure tree analysis for Tool safety issues 50 vi Figure 12 Fine blanking tool 50 Figure 13 Magnet 51 Figure 14 Failure tree analysis for Oil leakage issues 52 Figure 15 Quality's loss Pareto chart 53 Figure 16 Element with Break out issues 54 Figure 17 Critical / Functional part in side tool 54 Figure 18 Chipped Punch 55 Figure 19 Failure tree analysis for Break out issues 55 Figure 20 The Element with Damage Ejector issues 56 Figure 21 Critical / Functional part in side tool 56 Figure 22 Failure tree analysis for Damage Ejector issues 56 Figure 23 Failure tree analysis for Stuck conveyor Fine Blanking issues 58 Figure 24 Conveyor 58 Figure 25 Monthly OEE comparison 61 Figure 26 Fine Blanking OEE Index in March 2023 62 Figure 27 Availability loss before and after improvement 62 Figure 28 Quality loss before and after improvement 63 vii