Question: A semi - automated assembly machine, assembles and welds automotive components for a single shift of 8 hours, 5 days a week; planned throughput =

A semi-automated assembly machine, assembles and welds automotive components for a single shift of 8 hours, 5 days a week; planned throughput =275 units/hour; actual output =2200 units/week. Calculate Overall Equipment Efficiency. (8 marks)
The following losses are encountered during assembly:
>Incorrect assembly causes the machine to stop and needs re-set on average 6 times/hr. where 4 unit and 8 minutes are lost.
>Worn out electrodes are to be replaced once per week, it takes 75 minutes when 45 units are scrapped
>Burst out cooling hose causes a machine breakdown once in a month and replacement takes 6.25 hours
>Misaligned fixture causes a loss of 220 units/ week
>For different size parts, fixtures to be removed and replaced and electrode position to be adjusted 3 times/week which takes 3hours where 40 units are scrapped each time
>Actuating cylinder sometimes sticks for 35 minutes/adjustment causing production delay which takes double cycle time
>Application of rust protective spray by operator stopping the machine at the start and end of the day takes 8 minutes each time
>Limit switches corrode once in every 7weeks stopping the machine and replacement takes 330 minutes.

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