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1 Actual Cycle time = 1


Actual Production Speed 50
= 0.02
:
x 100 AM Ratio = 80 x 100
100
= 80%
: (%)
Available Time x 100 %Asset Availability =
Total Time 10,080
= 85.71%
: (%)
Used Time x 100 %Asset Utilization =
Total Time 10,080
= 79.36%
: (%)
(Loading Time - Downtime) 480 - 60 = 420
Loading Time Downtime = 20
%Availability Rate = (420 - 20) x 100
420
= 95.24%
: (%)
Available Time x 100
Total Time 10,080
= 85.71%
: (%)
Breakdown Time x 100 100
Operation Time 7,500
= 1.33%
: (%)
10 ( 1 )
= 50 ( 7 )
:

@average (CleaningTime) @average(30,40,35,30,40)


= 35
:

Actual Output Effective Time = 84,400


Specific Speed 185
= 456.2
:
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Effective Time x 100 7,500-300 = 7,200


Total Time Effective Time = 7,200-200 = 7,000
%Effective Utilization = 7,000 x 100
10,080
= 69.40%
: (%)
Production Volume 200 ton
Manhour 20 Manhour
= 20 ton/Manhour
: ton/Manhour
Last Breakdown Date - Previous Breakdown Date 31/7/03-1/7/03
= 30
30 x 24
= 720

Reproduction Date & Time - Failure date & time 31/7/03(12.00am.) - 31/7/03(11.00 am.)
1

10

( YTD)

10,000 10,000
89.25%
: (%)
Effective Time x 100
Operation Time 7,500
93.33%
: (%)
Operation Time x 100
Total Time 10,080
74.41%
: (%)
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(Theoritical Cycle Time x Actual Output) x 100 (0.48 x 800) x 100/400


Operation Time = 96%
: (%)
Effective Time
Production Time 7,200
= 97.22%
: (%)
Production Time x 100
Total Time 10,080
= 71.43%
: (%)
Total Output - Total Rejection 100,000 - 100 pcs
= 99,900 pcs.
: (ton) (case) (piece) (kg)
(unit)
(Actual Output - Defect) x 100
Actual Output 84000
= 97.62%
: (%)
1 1
Refernce Production Speed 60
= 0.0167
:
Rework x 100
Actual Ourput 10000 kg
= 1
20
2,000
= 1%
: (%)
Effective Time x 100
Running Time 7,160
= 97.77%
: (%)
Effective Time + Setup & Adjustment Time
= 7,160
:
Waste x 100
Actual Ourput 20,000 kg
= 1.00%
: (%)
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= @Average(
)
:
= @Average( QA
)
:
(USL - LSL)
6S 6 x 0.530094
= 0.628819
:
Cpu Cpl
3S
(11.09 - 10.09)
3 x 0.530094
0.572225
(y - LSL)
3S
(10.09 - 9)
3 x 0.530094
0.685413
0.572225
:
Defect x 100 2,000 x 100
Actual Output 84,000
2.38%
: (%)

: Kaizens
Total Rejected Product x 100 100
Actual Output 1000
= 10%
: (%)
(Actual Output-Non Conformance Product) x 100
Actual Output 1000
= 90%
: (%)

:
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Total Rejection Case by Customer =

:
QA
:
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Production Cost+BPS Conversion

=
: baht/ton

:
Cost of Poor Quality + QA Conversion 53,000 baht +100,000 baht
= 153,000 baht
: baht
Sum of {(Refected Products & Defects & Defects x Cost of
{(Product A 2,000 pcs. x 10 baht) +
Product)} + (Waste x Cost of Waste)}
(Product B 1,000 pcs. x 20 baht) + (Product
C 300 pcs. x 30 baht)} + Waste 200 kg x 20
baht)}
= 53,000
:
Sum of Cost Saving/
:
Sum of Saving 3,000,000
Sum of Investment 100,000
30
:
400,000
Ton Product 1,000 Ton Product
= 400 Ton Product
: Ton Product
(@Average(Actual Weight) - Standard Weight) x 100
Standard Weight 100 gm
= 5%
: (%)
=AVERAGE(Actual Weight) - Standard Weight
= 5 gm
:

= 1,200,000 baht
= 1.2 M.baht
: m.Baht
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Innovation Rate =
= 500,000 baht
= 0.5 M.baht
: m.Baht
300,000
Ton Product 1,000 Ton Product
= 300 Ton Product
: Ton Product
Materials Cost + Production Cost
Product Volume 1,000 ton
= 3,400 baht/ton
: baht/ton
(DL + DP + OPHC) 1,000,000 baht+500,000 baht+100,000baht
PV 1,000 ton
DP = Depreciation Production = 1,600,000 baht
PV = Product Volume 1,000 ton
= 1,600 baht/ton
: baht baht/ton
(Product Indirect+Other Production Cost) 200,000 baht+50,000 baht
Product Volume 1,000 ton
= 250,000 baht
1,000 ton
= 250 baht/ton
: baht baht/ton

(Utility+Repair&Maintenance+MWHT+OPS)

PV 1,000 ton
= 2,730,000 baht1,000 ton

: baht baht/1,000 ton


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Innovation Volume
Production Volume 20,000 ton
= 10%
: (%)
Plan Output-@ABS(Actual-Plan Output) x 100
Plan Output 20,000
= 90%
: (%)
No. of Hits x 100
No. of Production Runs = 80%
: (%)
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(LTA+RWC) x 100,000 hours


Working Hour 300,000 per 100,000 hours
= 8.33 per 100,000 hours
: 100,000
x 100 10
200
= 5%
: (%)
Lost Time Day
: day
Minor Accident
: case
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x 100
100
= 5%
: (%)

100 ( )
= 10 cases/head/year
= 10
: cases/head/year

Plant
: Kaizen/Plant

: case

: Kaizen/Plant
P-M Analysis 100 Kaizens/Plant
: Kaizen/Plant

: case

W5 Image 50 Kaizens/Plant
: Kaizen/Plant
Number of Suggestion x 100
Number of Employees 100
= 20 cases/head/year
: cases/head/year