Experience in improving equipment performance at CADIVI Tan A

In the period of 2019 – 2020 with the goal of annual revenue and profit growth, the management of CADIVI Tan A Company (a branch of Cadivi Dong Nai One Member Limited Company) was not afraid to experiment with new methods to improve high production efficiency.

While product prices are increasingly competitive, to increase sales, there is no other way to increase output. To increase production, businesses either need to invest in more equipment (high investment costs) or apply solutions to improve production efficiency with available resources. CADIVI Tan A chose the second option.

Accordingly, the Company has collaborated with the consultants of the Vietnam Productivity Institute to find ways to improve the efficiency of medium voltage cable production line.

• Step 1: Form an improvement team consisting of the chief, deputy, technical staff, production team leader.
• Step 2: Train general awareness of the role of technology and equipment in productivity enhancement; common equipment-related losses; methods and tools to collect data and calculate OEE to evaluate current equipment performance.
• Step 3: Collecting data to calculate OEE in May 2019;
• Step 4: Analyze OEE data. The data shows that downtime is mainly due to changes in specifications of products, tools and materials (accounting for 60-80% of total downtime); reasons such as stopping cleaning, waiting for materials, lack of operators (accounting for 20-40% of the total stopping time); stop due to unexpected equipment failure (less than 15% of total stop time).
• Step 5: Propose solutions to improve equipment efficiency: Combining “Quick Conversion”, “Self-managed Maintenance” and improving the planning and monitoring process of production plans and progress.

Perform quick conversions

The group conducted video recording and operation analysis of the product conversion process at MB.90-1.

Based on the method of work sampling (Work Sampling) and the principle of improvement of ECRS, the expert group has guided the enterprise to analyze the current conversion process of the MB.90-1 machine into big tasks. Then proceed to record and analyze each job, and distinguish task E (can be performed while the machine is running) and task I (available only when the machine stops).

Based on the differentiation of tasks, the improvement team will shorten, rearrange and refine tasks E (do first), I (do later) and minimize waste due to travel and transportation. Thanks to rational change of processes from I (do later) to E (front work) and tool and tool improvement for de-molding work, machine downtime has been reduced by 39.75% (from 40). minutes to convert before improvement, only 24.1 minutes after improvement).

Apply autonomous maintenance

Self-managed maintenance is a group of maintenance activities performed by the operators themselves. The CADIVI Tan A improvement group focuses on instructing workers to perform routine initial cleaning to detect machine or work area anomalies through AM card suspension – with information and instructions specific to all participants easily identified and tracked. Thereby, any even the smallest abnormalities affecting the normal working conditions of the equipment or work area will be detected before turning into larger incidents.

These sources of dirt and potential risks, once detected and analyzed, are isolated and removed from the machine and work area. For areas that are difficult to clean, the team of experts has improved and researched to improve cleaning methods and tools. Then standardize by building a set of standards for Cleaning – Checking – Lubrication for the operation of machinery and equipment of CADIVI Tan A factory. As for the defects in machines and equipment, the cause analysis will be analyzed and a specific plan to be dealt with with the completion time and the detailed assigned operator. Finally, the results of the correction will be confirmed and monitored by management.

With the above solutions, OEE equipment has increased by an average of 20%, helping the overall plant efficiency reach over 70%. From this initial success, CADIVI Tan A is determined to make other improvements to improve the efficiency of production and business of the business.

Productivity and Quality Office