Productivity Improvement of Industrial Pipes Insulators

Abstract

The production processes of heat insulation are studied in order to improve the productivity of the production plant. It has been found that to increase the productivity an improvement in the manual processes to a more efficient processes, equipment and tools should be done. The DMAIC methodology was used. Based on this methodology a tool was designed to simplify two processes (cutting and rolling process). Therefore, the cutting room was dispensed and the number of workers were reduced by two workers which was 11.1% of the total number of workers. The new model was designed and simulated by the Solid Work program. Based on simulation the time used for cutting and rolling to produce one piece with the new tool is estimated to be 3 minutes instead of 8 minutes and the new takt time was 5.53 minutes instead of 8.58 minutes. The previous production rate is 38 units per day (10,000 units per year), The new production rate is 59 units per day (15,500 units per year), the increase percentage of production is 55% more.