Improving The Equipment Efficiecy (OMR Machine-A Case of Education Board Computer Centre, Dhaka, Bangladesh

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Master of Advanced Engineering Management
Improvement in Equipment Efficiency: Case of Education Board Computer Centre
By SYED MD. SHAEEDUZZAMAN
This thesis has been submitted in partial fulfillment of the requirement for the degree of Master of Advanced Engineering Management (AEM).
Department of Industrial and Production Engineering (IPE) Bangladesh University of Engineering and Technology (BUET), Dhaka-1000, Bangladesh. December 2008
The thesis titled Improvement In Equipment Efficiency: Case of Education Board Computer Centre submitted by Syed Md. Shaeeduzzaman, Roll No. 040408116P, Session April 2004 has been accepted as satisfactory towards partial fulfillment of the requirement for the degree of Master of Advanced Engineering Management on November 05,2008.
BOARD OF EXAMINERS
Dr. A.K.Masud Associate Professor Department of Industrial and Production Engineering Bangladesh University of Engineering and Technology
Chairman (Supervisor)
Dr. Abdullahil Azeem Associate Professor Department of Industrial and Production Engineering Bangladesh University of Engineering and Technology
Member
Dr. Nafis Ahmad Assistant Professor Department of Industrial and Production Engineering Bangladesh University of Engineering and Technology
Member
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DECLARATION
It is hereby declared that this thesis paper or any part of it has not been submitted elsewhere for the award of any degree or diploma.
Syed Md. Shaeeduzzaman
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ACKNOWLEDGEMENT
This study would not have been possible without the support and guidance of my project supervisor Dr. A.K. M Masud, Associate Professor, Department of IPE, BUET. I would like to take this opportunity sincerely thank him for his valuable advice, constant support and encouragement in completing the project.
My sincerest gratitude to all the individuals of EBCC, Dhaka, who directly or indirectly helped me out in many instance through giving their precious time for consultancy, who are always their provide support, ideas, their constructive criticism towards my study.
I would also like to thank my respected teachers of the department, classmates, friends and family members who directly or indirectly gave encouragement and support in completing my job. In addition, I would be grateful to my Division Signal and Telecom Engineer, Bangladesh Railway, Paksey, Pabna Mr. Asim Kumar Talukder. However, my express thanks to all person of EBCC and Railway Subordinate of office member, Paksey because at final moment of this job I joined in Bangladesh Railway getting a better opportunity in my service from EBCC.
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ABSTRACT
Education Board Computer Canter (EBCC), a sister concern of all Education Boards of Bangladesh has been done Examination related jobs; e.g., registration processing, coding of answer scripts, publication of result, certificate and transcript printing etc. since 1994. EBCC use Optical mark reader (OMR) to achieve these aspects for accurate, timely, and cost-effective data collection. This study will briefly trace the problems in data collection process in EBCC. A detailed explanation will be made of how EBCC are able to maximize their usage of OMR with existing system by using prevailing method Total Productive Maintenance (TPM). Also gives a straightforward scheme for the countermeasures of data collection process using the Pareto analysis system by means of Why Why Because Logical Analysis (WWBLA) techniques as well as exposed the improvement of Overall Equipment Efficiency (OEE) of the process.
-: TABLE OF CONTENTS:Page No. Chapter-1: Overview of Education Board Computer Center 1.1 Introduction 1.2 Objective of the Project Chapter-2: Literature Review 2.1 Introduction 2.2 O.M.R System in Result Processing and Student Registration 2.3 Methodology of the case Study 2.3.1 Total Productive Maintenance 2.3.2 Overall Equipment Efficiency 2.3.3 Why Why Because Logical Analysis Chapter-3: Education Boards & EBCC 3.1 Introduction 3.2 History of the Education Boards 3.3 Structure of the Education Boards 3.4 Activities of the Education Boards 3.4.1 Revenue and Expenditure 3.4.2 Human Resources of the Education Boards 3.4.3 School and College Administration 3.4.4 Rules of Business 3.5 Computer System in Public Examination Process 3.5.1 Organization Chart of EBCC 3.6 Activities of Education Board Computer Center (EBCC) 3.7 Disbursement of Education Board in favor of Computerized Result Processing System Chapter-4: Optical Mark Reader (OMR): Scanning System 4.1 Introduction 4.2 AXM- 995 OMR Specifications 4.3 Disposition of the parts of AXM-995 OMR 4.4 Application of Optical Mark Reader 4.5 Disposition of the OMR forms used in EBCC 18 18 20 22 23 9 9 10 10 11 11 11 11 13 13 14 15 4 4 5 6 8 8 1 2
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4.6 Data Processing System in EBCC 4.7 Scanning System in EBCC 4.8 Optical Mark Reader (OMR) - Problems and Errors Chapter-5: Fault Analysis: Case Study 5.1 Introduction 5.2 Functions of TPM 5.3 The Advantages of TPM 5.3.1 TPM - TQM (Total Quality Management) Many Similarities 5.4 Generalized Losses of a manufacturing organisation 5.4.1 Addressing the Six Big Losses 5.5 Importance of Overall Equipment Effectiveness 5.5.1 OEE Factors 5.5.2 Calculating OEE 5.6 Identification the fault process of OMR scanning system 5.6.1 Check Sheet 5.6.2 Analytical Techniques of Fault analysis 5.6.3 Pareto Analysis 5.6.4 Cause Effect and Pareto Integration 5.6.5 Identification the significant Losses in OMR scanning 5.7 Calculating OEE for OMR 5.7.1 Factors influence OEE in OMR Scanning System 5.7.2 The Stages of WWBLA 5.8 Results Chapter 6: Conclusion & Recommendation References System
28 30 33
37 37 38 40 40 42 43 44 48 49 50 54 54 55 55 57 58 59 64 66 68
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LIST OF TABLES
Table 1: Scanning and related picture of EBCC in S.S.C Examination 2007 Table 2 : Scanning and related picture of EBCC in H.S.C Examination 2008 Table 3 :Shorting Expenses of S.S.C Examination 2007 & H.S.C Examination (in BDT) Table 4:Scanning Expenses of S.S.C Examination 2007 & H.S.C Examination ( in BDT) Table 5: General Technical Information of AXM 995 OMR Table 6: Electrical Characteristics of AXM 995 OMR Table 7: Mechanical Characteristics of AXM 995 OMR Table 8: Dimensions of the Machine of AXM 995 OMR Table 9: Printer Characteristics of AXM 995 OMR Table 10: Replacement parts list of AXM 995 OMR Table 11: Similarities and difference between TQM and TPM Table 12: Generalized Losses of a manufacturing organisation Table 13: Overall Equipment Efficiency Factor Table 14: Representation World Class OEE Factor Table 15: Period & Phase the OMR machine stop in study period. Table 16: Pareto Chart for Six major Losses in OMR Scanning System Table 17: Major Causes of machine stoppages Table 18: Why Why Because Logical Analysis (WWBLA) worksheet.
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LIST OF FIGURES
Figure 1: Organization Chart of EBCC Figure 2: AXM-995 OMR (Front End) Figure 3: AXM-995 OMR (Back End) Figure 4: AXM-995 OMR (Light Barrier Sensors) Figure 5: H-type form Figure 6: E-type form Figure 7: SIF-type form (top side) Figure 8: SIF-type form (bottom side) Figure 9: M Type OMR form Figure 10: P Type OMR form Figure 11: Flow chat of Data Processing system in EBCC. Figure 12: Flowchart of scanning system Figure 13 : A Tag sheet used in EBCC Figure 14: Impact of maintenance on competitiveness Figure 15: Overall Equipment Effectiveness Model Figure 16: Check sheet use for counting the No. of Time(s) the fault Occurred Figure 17: Check sheet use for counting the Total Stopping Time (in Min.) of the OMR. Figure 18: Pareto Chart for six major losses Figure 19: WWBLA Overview Figure 20: Pareto Chart for major causes of machine stoppage
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ABBREVIATIONS
EBCC SSC HSC BISE OMR TPM OEE GOB IT BISE SIF MCQ HEX TQM NG WWBLA
Education Board Computer Center Secondary School Certificate Examination Higher Secondary Certificate Examination Board of Intermediate & Secondary Examination Optical Mark Reader Total Productive Maintenance Overall Equipment Efficiency Government Of Bangladesh Information Technology Board of Intermediate and Secondary Education Student Information Form Multiple Choice Questions Hexa Decimal Number Total Quality Management Not Go Why Why Because Logical Analysis
Chapter-1: Introduction
1.1 Introduction: Education Board Computer Center (EBCC) is the sisters concern of eight educations boards. All these autonomous bodies are functioning under a same platform, example of which is the simultaneous result publication. Chairman of Dhaka Education Board governs functionalities of it as an additional appointment and Senior System Analysts are in charge of different boards. All the boards are combined here for security purpose and to facilitate simultaneous jobs of result processing, to exchange ideas, views and technologies directly. It acts as a bridge among the boards [1]. The Boards of Intermediate and Secondary Education including are responsible for conducting the public examinations such as Secondary School Certificate (S.S.C) and Higher Secondary Certificate (H.S.C) level public examinations. The Boards are also responsible for the reorganization of the private sector educational institute. To publish the result of S.S.C. and H.S.C. Examinations more correctly and fast, Computer Center of Bangladesh University of Engineering and Technology (BUET) was given the responsibilities of publishing the results of two public examinations in 1994 of then four boards (Dhaka, Rajshahi, Comilla and Jessore) with computer technology using coding mechanism and O.M.R. (Optical Mark Reader) technology. Then in 1995 Education Board Computer Center started its operation at Dhanmondi, Dhaka with the own work force of respective boards. Now Dhaka Board, Rajshahi Board, Chittagong Board, Madrasah Board, Barisal Board under Jessore Board and Sylhet Board under Comilla Board are functioning at Computer Center. Fast result publication of S.S.C. and H.S.C. Examinations of the boards, registration processing, preparing admit card, tabulation sheet, transcripts and certificates and other examination related jobs are done in this center. Here the operations are performed through computerized system with the help of O.M.R. technology. Since commencement, it has been publishing the result before the scheduled time and publishing the result in international standard grading system of S.S.C. Examination since 2001 and of H.S.C. Examination since 2003.
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Education Board Computer Center (EBCC) is the largest O.M.R. mechanism based computerized setup for public examination perhaps in Asia. At present 34 high-techs, O.M.R. machines are operating here. Moreover, it is coping pace with the fast changing technologies in both software and hardware. EBCC is mainly an IT (Information Technology) organization and its main structure based on OMR machine. Therefore, in this case study efficiency improvement of OMR machine is regarding a crucial issue. In today's fast-paced information-driven society, the need for accurate, timely, and cost-effective data collection is very critical. Optical mark reader (OMR) systems can be used to achieve these aspects. This case study describes the development of a low-cost and high-speed OMR system for marking multiple-choice questions and related arrangement. Effective mark detection and verification algorithms have been developed and implemented to achieve real-time performance at low computational cost. There are some identified problems while operating the OMR machines. That is why the production target cannot achievable every time. The problems of OMR machine are Sheets are not accepted, unidentified sheet, Length error, Jam before head, Jam under head etc. Those are being the faulty input material of OMR machine [2]. Productivity is getting down due to improper use of production management. Lake of schedule maintenance, continuous production also hampers [3]. Total Productive Maintenance (TPM) is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. The goal of TPM is markedly increase production, while at the same time, increasing employee morale and job satisfaction as well as increase the efficiency of the system. TPM [4] deals with the tools and techniques, which help identifying and reducing equipment losses to maximizing overall equipment efficiency (OEE) [5]. This study describes the development on how the TPM tools and techniques can be applied in EBCC for improving efficiency (OEE) of the OMR machine. 1.2 Objective of the Project: To implement the IT (Information Technology) in all sectors of GOB (Government of Bangladesh), at fast GOB is executing IT policy in the Education Sector. On this way, GOB (Government of Bangladesh) was given the responsibilities of publishing the results of S.S.C. and H.S.C. examinations more correctly and fast to the -2-
computer center of Bangladesh University of Engineering and Technology (BUET). In 1995, this job is assigned to EBCC. EBCC is committed to do all the job assign by the authority timely, accurate and cost effective way. One of the technologies in common use at EBCC is optical mark reading (OMR). Day by day, the area of business of EBCC is increased with the change of IT (Information Technology). In addition, the OMR usage has increased with the system. The need has arisen for additional user services support in the areas of OMR documentation, education, utility programming, and office procedures. Therefore, the efficiency improvement of OMR machine is a vital topic. On this concern of the OMR process, the objective of thesis is following: To identify the different fault of the OMR process. Root cause analysis of the process. Pareto Analysis of the process. To improve quality of the process. To reduce production cost by means of reducing time loss.
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Chapter 2: Literature Review

2.1 Introduction: Education Boards objective is to provide quality service in Secondary and Higher Secondary level of education specially in conducting examinations and to maintain the standard of educational institutions. For these reasons, it introduced computerized system in result processing and registration, international standard grading system, result publication through website and so on. An optical mark reader has a document feed hopper and several stackers. It works with those documents, which are printed with mark positions on its specified areas. A mark made in a position using a dark pencil or black ink is read by OMR. The OMR can read about 10,000 documents per hour. It is a document reader and is commonly used for quick evaluation of Multiple Choice Examination answer sheets [1]. 2.2 O.M.R System in Result Processing and Student Registration: EBCC is used OMR form for collecting data. Data is captured from compatible scripts by scanning through O.M.R. (Optical Mark Reader) machine. There is no scope of inaccuracy in information gathering. The forms are machine-readable where a student has to fill up few circles to provide personal information (viz. name, fathers name, date of birth, school/college code etc.). These filled circles are read through O.M.R. and information is gained which makes the database. In this method of mark recognition, a thin beam of light is directed on the surface of the paper, which contains dark pencil, or black ink marks. Since the dark mark absorbs comparatively more light than the surrounding area, it reflects laser light to the detector. This reduction in reflected light helps to recognize the mark. Answer script contains 31-digit special code called litho-code. Moreover, the examiners when given for evaluation cannot recognize the script that to which student or to which school/college it belongs to. Because the portion of the O.M.R. compatible form containing students roll, registration and subject code is detached from the answer script after the exam and sent to computer center. As the examiner cannot identify the student or
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institution of the answer script, student gets justification in evaluation. After evaluation head examiner sends the second portion of O.M.R. readable form of the answer script to the computer center. In this system, modern and practical oriented litho-code is used which is a random code with 31 digits and unique for every scripts. This litho-code is matched by computer software and the mark against a roll no. is got and thus tabulation is made based on that. In computerized system, no data is entered manually. Each information is entered by scanning through O.M.R. machine. Therefore, there is no scope of mistake in information gathering and result processing. Result is published correctly and fast by the present computer system. For this reason, students get opportunity to get admission in colleges/universities timely, which helps to reduce session jam. There is no session jam in S.S.C. and H.S.C. level. 2.3 Methodology of the case Study: In this study, firstly all sections of the EBCC are pointed out for assessment. It is observed that the goal of all factory improvement activity is to increase productivity by minimizing input and maximizing output. Output refers not only to increased productivity but also to better quality, lower costs, timely delivery, improved industrial safety and hygiene and to a more a favorable working environment. At this point equipment and machinery are the crucial factors increasing output. Productivity, quality, cost and delivery, as well as safety, hygiene, environment, and morale are all influenced significantly by equipment conditions. The goal of maintenance management is to enhance equipment effectiveness and maximize equipment output. It strives to attain and maintain optimal equipment conditions in order to event unexpected breakdowns, speed losses and quality defects in process. Overall efficiency, including economic efficiency is achieved by minimizing the cost of upkeep and maintaining optimal equipment conditions throughout the life of equipment. Therefore, the steps that were followed are: Identification of major losses Identification of significant losses by Pareto analysis Calculation of Overall Equipment Efficiency(OEE) Reduction of losses with analytical Techniques.
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At first, all the sections of EBCC are studied. Then it is identified and reduced equipment losses to maximize overall equipment efficiency (OEE) by using the tools and techniques of Total Productive Maintenance (TPM). From the different analytical techniques used in TPM for improvement, here we used WWBLA (Why Why Because Logical Analysis). 2.3.1 Total Productive Maintenance: After the Second World War the Japanese Industry realized, that they must have a higher quality in the products to compete on the world market. The Japanese companies were importing the management and manufacturing technologies from the USA, and then tailored them to their needs .To be effective in the maintenance their imported the concept of the preventive maintenance from the USA for over 40 years ago. Later were also the principles of the productive maintenance, the maintenance prevention and the reliability engineering imported. The company Nippondenso co. was the first to start with the productive maintenance , 1969 they introduced TPM , to meet the challenges in growing amount of the automation and the new demands , the automation was creating to the maintenance and to the whole company. In 1971, the same company got the first
Distinguished Plant Prize , given by the JIPM, Japanese Institute of Plant Maintenance (Nakajima, 1988). To eliminate waste, Toyota became one of the first companies to implement TPM Nakajima, 1988). Toyota measures six categories of equipment losses throughout its production System [4]. These are (also Fredendall 1996): Equipment failures: Sporadic and chronic equipment failure / breakdowns sudden and unexpected sporadic breakdowns are infrequent and result from the deterioration of the mechanical and electrical operating components. For example a hydraulic error in tool changer of the CNC - machine tool or an electrical error in the CNC - control etc. Chronic breakdowns, which are the result of the defects in equipment, tools, materials, and operating methods, occur frequently, resulting in small amounts of lost time. For example, unpredicted cutting tool breakdowns in the chip- breaking of difficult materials, mistakes in the choice of the manufacturing methods etc. Setup and adjustment: Make-ready and equipment adjustments. With shorter run lengths, smaller batches and more make-readies, reduction in make- ready time and new job adjustments, emphasis is being placed on time - to - good
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counts. For example when a new job comes to a machine tool, tooling and fixtures have to be changed. Idling and minor stoppages: Material abnormalities and slight machine malfunctions that can be overcome by replacing materials or resetting press components. For example, incoming material has not equal quality; the automating tool changer is not working properly. Reduced speed: For example while numerous reasons are advanced for running presses and bindery equipment at slower than rated speeds , less than label speeded operations represent a productivity loss . Defects in the process: Defective products, for whatever reason
must be treated as a loss and therefore eliminated. For example, dimensions a dimension are not inside of the tolerance area. The products have some surface damages etc. Reduced yield: start up losses. Start - up loss is lost time after the make-ready is complete and production sheets / signatures are being counted, but at a reduced speed. The losses are generally accepted as a process variable, but account for considerable productivity loss [3]. These six losses are combined into one measure of overall equipment effectiveness (OEE), which is:
OEE = Equipment availability x Performance Efficiency Rate of Quality Products
In the year, 1995 there were are about 800 companies or company units using the TPM in Japan Johansson, 1996). In addition, the European companies have started to apply TPM; one of the very first has been the Swedish car manufacturer Volvo in the Gent factory in Belgium. In Sweden especially the IVF (Institute for verkstadsteknisk forskning) has made big efforts to implement TPM in the Swedish companies, also in the small - and medium Sized enterprises. 2.3.2 Overall Equipment Efficiency: OEE (Overall Equipment Efficiency) is a "best practices" way to monitor and improve the efficiency of any manufacturing or operating processes (i.e. machines,
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manufacturing cells, assembly lines). OEE is simple and practical. It takes the most common and important sources of manufacturing productivity loss, places them into three primary categories and distills them into metrics that provide an excellent gauge for measuring where we are - and how we can improve! OEE is frequently used as a key metric in TPM (Total Productive Maintenance) and Lean Manufacturing programs and gives you a consistent way to measure the effectiveness of TPM and other initiatives by providing an overall framework for measuring production efficiency [5].
2.3.3 Why Why Because Logical Analysis: WWBLA technique is a worksheet which identities the root causes of problem [5]. In this technique, each major problem is considered separately and a worksheet is prepared. For each problem, a cause is identified and called it first factor for problem. Then it is verified whether it can be divided into further root causes. If it is possible, then it is marked as G. Here, G stands for Go. Then a second factor for problem is identified is verified. In this way, a third, fourth problems are identified. If it is not possible to identify further, then verification is marked as NG (Stand for No Go). Finally, countermeasures are identified for each causes of problem [6].
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Chapter-3: Education Boards & EBCC

3.1 Introduction: According to the ordinance of the board, The East Pakistan Intermediate and Secondary Education Ordinance, 1961 (East Pakistan Ordinance No. XXXIII of 1961) and its amendments No. XVI of 1962 and No. XVII of 1977, it is responsible for the organization, regulation, supervision, control and development of Intermediate and Secondary level public examinations and educational institutions. 3.2 History of the Education Boards: The Board of Intermediate and Secondary Education (BISE), Dhaka was established on 7 May 1921 according to the recommendation of Sadler Commission. Intermediate colleges and high schools in Dhaka city and Islamic intermediate colleges and high Madrasah of greater Bengal were under control of that board. An advisory board made by the director of public education department of greater Bengal was given the governance of that board. Dhaka Board was dissolved in September 1947 by a government order. Its name was changed to East Bengal Secondary Education Board in 1955 and it was live until 1961. Scope of this new board was limited to secondary level education of then the East province of Pakistan and control of intermediate education was shifted to the University of Dhaka. Responsibility of intermediate education was given to the board from the university in 1961 and board was named Board of Intermediate and Secondary Education, East Pakistan. In addition, after liberation it was named Board of Intermediate and Secondary Education, Dhaka with the scope of operation within Dhaka division. By the rise of population of the country and to meet with the global change, government of Bangladesh (GOB) has given deep look on education sector. To make easy of operation of the job Govt. day by day increase the numbers of the education boards. At present Rajshahi, Comilla, Jessore, Chittagong, Barisal, Sylhet and Madrasah the seven other education
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boards are working on the same fundamental policy of the first education board of the country. Very soon a new education board namely Dinajpur Education Board is going to start its journey with the same platform. 3.3 Structure of the Education Boards: All Boards of Intermediate and Secondary Education (BISE) are an autonomous body and its business functions under the supervision of Ministry of Education of GOB. The Chairman is the Chief Executive Officer of the board. The Chairman and eleven members of different categories comprise a board committee approved by the ministry for three (3) years, which is responsible for smooth functioning of the board. Moreover there are several more committees formed according to ordinance and related rules, viz. (1) Academic Committee, (2) Examination Committee, (3) Disciplinary Committee, (4) Finance Committee, (5) Selection Committee, (6) Regulation Committee, (7) Appeal and Arbitration committee, (8) Name and Age Correction Committee and so on. 3.4 Activities of the Education Boards: Preparation and arrangement of registration for students of class IX and XI for two public examinations- S.S.C. and H.S.C. and result publication of those examination within a specific duration. After publication of result of the two examination the education board are distributed the tabulation sheet, academic transcript and certificate among the students via schools and colleges. Reserving the interests of teachers jobs through inspection of educational institutions, investigation, appeal and arbitration and considering the extension of job of non-government qualified teachers. Inspecting newly established educational institutions and giving approval, renewing approval, approving the managing committee is of schools and governing bodies of colleges and permitting the enrollment of students according to the government rules. Examination related overall activities; viz. question papers preparation, revision, printing of question papers through
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B.G. Press, sending the question papers to the centers timely through respective Deputy Commissioners with secrecy, distribution of answer scripts, which include O.M.R. (Optical Mark Reader) compatible forms among examiners after the exam, and arrangement of payment of remuneration of related teachers. 3.4.1 Revenue and Expenditure: The education boards are a self-depended institution. Its sources of revenue are examination, registration, permission, approval, renewal of approval, affiliation etc. The Government of Bangladesh (GOB) approves the annual budgets made by the boards. It takes no financial help from the GOB. 3.4.2 Human Resources of the Education Boards: Chairman and some other top-level posts are filled up by the senior officers of Education Cadre on deputation. Rest of the officers and employees are the own staff of the board, job of which is regulated by the service rule of the boards. Number of officers and employees are fixed based on the volume of responsibilities. 3.4.3 School and College Administration: Permission for establishment of new schools and colleges (Private) and then academic approval are given by the boards. Moreover, approval of managing committees of schools and colleges, disposal of their disputes, inspection and supervision are few of its important businesses. 3.4.4 Rules of Business: To start a new school or college, application must be submitted to the boards four months before the commencement of academic year defined by government. Fees of the board have to be submitted in favor of Secretary of board through C.D. of Bank of each, B.I.S.E. or Demand Draft respective Bank. No other mode of payment is accepted. Attempts have to be taken to form new managing committee/governing body before expiration date of managing committee/governing body and have to be submitted to board within the scheduled time for approval.
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a) Age of student for enrollment in class IX is at least 12 (Twelve) years. Any student successfully completing class VIII from any approved school can enroll in class IX. b) Generally direct (First) enrollment in class IX is not permissible. But if anybody can show the certification of Headmaster of the relevant school that he or she has acquired the knowledge equivalent to class VIII, can be enrolled in class IX within the 31st March of the academic year with the special consideration and prior permission of the education board. c) Age of student for appearing in the S.S.C. Examination is at least 14 (Fourteen) years on 1st January of the year of examination. d) Student above 18 (Eighteen) years old cannot study in class IX and student above 19 (Nineteen) years old cannot study in class X. e) There is no age limit for studying in Higher Secondary level and for appearing in the Higher Secondary Examination. f) It is possible to appear in the H.S.C. Examination as an irregular (Private) examinee three years after passing the S.S.C. Examination. g) If any student, passed from foreign system is willing to enroll in class XI of any approved college of Bangladesh, has to take prior permission from the Inspector of Colleges of the board. h) If any student passed from foreign institute (board, university) is willing to enroll in class XI of any approved college of Bangladesh has to apply for equivalency of his acquired degree in the board. i) For opening any new subject in any school/college, taking prior permission from the concerned department of the board is necessary. j) Correction of Errors in Registration Card and Admit Card: A student has to fillup the O.M.R. readable SIF (Student Information Form) correctly after being admitted into class IX and XI. Then he has the option to correct any errors scrutinizing the printout copy. No application for change will be accepted after delivery of registration card and admit card.
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3.5 Computer System in Public Examination Process: Examination related jobs; e.g. registration processing, coding of answer scripts, publication of result, certificate and transcript printing etc. have been done through computerized system using O.M.R. (Optical Mark Reader) technology since 1994. For these purposes, there is a combined computer center in Dhaka for all education boards named Education Board Computer Canter (EBCC) at Dhanmondi. Chairman of any Education Boards assigned by the Ministry of Education of GOB is in charge of it as an additional duty. 3.5.1 Organization Chart of EBCC: Early we mention that EBCC is the sister concern of Education Board. Now we see the organisation chart of EBBC by the following diagram: Chairman
Sr. System Analyst
System Analyst Programmer

Asst. Programmer Asst. Programmer
Programmer
Asst. Programmer Asst. Programmer
Operator
Operator
Operator
Main. Engr.
Operator
Asst. Main. Engr.

Scanning Operators
Shorting Operators
Figure 1: Organization Chart of EBCC
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3.6 Activities of Education Board Computer Center (EBCC): Information is gathered through O.M.R. scanning of S.I.F. (Student Information Form) which is filled up by student and registration card is given. Computerized system has eradicated the registration complicacies and fake registration problem. Timely registration card distribution is possible in this system. Computerized admit cards are given to registration cardholder authentic students to sit for the examination. List is made to packet center-wise questions of S.S.C. and H.S.C. Examination, printed by B.G. Press, based on the number of students. Litho-code containing O.M.R. compatible form is enclosed with the answer script. It contains three portions. First portion includes examinees roll no., registration no., subject code, second portion contains evaluated marks by the examiner for that script and the third one has the evaluated marks and it is attached to the answer script. Three portions of the top sheet contain same litho-code. After the examination first portion of the answer script and M.C.Q. (Multiple Choice Questions) answer script (Only for S.S.C. Exam.) which is also O.M.R. compatible sheet are sent to computer center directly (with armed squad) or through registered mail. Packets containing first portions of O.M.R. compatible forms are received board-wise, sorted center-wise in computer sections of respective boards and data is received by scanning through O.M.R. machines. Marks for practical tests are also gathered through scanning of O.M.R. compatible forms. Answer scripts evaluated and scrutinized by examiners/head examiners contain marks in the second portion of the O.M.R. readable sheet, which is sent to computer center by the head examiner by hand. Data is gathered by scanning the sheets. The scanned data remains scattered. The result is published through litho-code matching of the first portion containing roll no., reg. no., subject code and the second portion bearing obtained mark. Tabulation sheet is given within 7 (Seven) days of result publication. Transcript is given within 1 (One) month of result publication. Original certificate is provided within two months of result publication. List of scholarships is prepared.
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Besides the tasks mentioned above, it provides various types of information and statistics as wanted by Ministry of Education, Directorate of Secondary and Higher Education, BANBAIS, Education Board and different organizations. 3.7 Disbursement of Education Board in favor of Computerized Result Processing System: There is a fixed expense of EBCC excluding the remuneration and fixed asset cost for the Computerized Result Processing System. Here we see the last two-job expense detail of EBCC by the following tables[1]:
Table 1: Scanning and related picture of EBCC in S.S.C Examination 2007
Board Dhaka Rajshahi Comilla Jessore Barisal Sylhet Chittagong Madrasha
Male Student 114523 101009 37023 53456 22712 13514 30376 55003
Total OMR Form Scanned 4122821 3636310 1332828 1924423 817639 486511 1093529
Female Student 107889 93320 35636 47546 23360 14570 28583
Total OMR Total Form Scanned Script 3884004 8006825 3359502 6995812 1282878 2615706 1711638 3636061 840942 1658581 524502 1011013 1028970 2122499 1211544 3191659
Total Student 222412 194328 72659 101002 46072 28084 58958 88657
1980115 33654 Total Examinee 7,23,514
Total Script/OMR from Scanned 2,60,46,497
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Table 2 : Scanning and related picture of EBCC in H.S.C Examination 2008
Male Board Student Dhaka 81802 Rajshahi 72149 Comilla 26445 Jessore 38183 Barisal 16223 Sylhet 9653 Chittagong 21697 Madrasha 39288
Female Student 71926 62213 23757 31697 15573 9713 19055
Total Script 3689472 3224688 1204848 1677120 763104 464784 978048 1481376
Total Student 153728 134362 50202 69880 31796 19366 40752 61724
942912 22436 538464 Total Examinee 5,61,810 Total Script/OMR From Scanned 1,34,83,440
Table 3 :Shorting Expenses of S.S.C Examination 2007 & H.S.C Examination (in BDT) Examination Board Dhaka Rajshahi Comilla Jessore Barisal Sylhet Chittagong Madrasha Sub Total Grand Total S.S.C 77500 60000 37500 39000 27000 30000 31250 52500 354750 H.S.C 5600 4500 2500 3250 2025 2250 2500 4500 Sub Total 736625 Total 83100 64500 40000 42250 29025 32250 33750 57000 381875
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Table 4: Scanning Expenses of S.S.C Examination 2007 & H.S.C Examination (in BDT)
Examination Board Dhaka Rajshahi Comilla Jessore Barisal Sylhet Chittagong Madrasha Sub Total Grand Total S.S.C 2402047 2098743 784712 1090818 497574 303304 636750 957498 8771447 H.S.C 110684 96740.6 36145.4 50313.6 22893.1 13943.5 29341.4 44441.3 Sub Total 17947397.00 Total 2512731.6 2195484.12 820857.24 1141131.96 520467.48 317247.48 666091.08 1001939.04 9175950
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Chapter-4: Optical Mark Reader (OMR): Scanning System

4.1 Introduction: In the market several types of OMR is available. At EBCC out of thirty-four OMR machines twenty-five nos. are the model of AXM 995 and the other nine nos. are the model of AXIOME- 880. In this case, study in EBCC AXM -995 types OMR machine was taken as sample machine. The AXM 995 has been designed in compliance with the European IEC safety and electronics regulations for data processing devices and in compliance with safety regulations applicable to terminals in office equipment environment. The machine can be used in permanent operation at office temperature. 4.2 AXM- 995 OMR Specifications: The following tables give the total over view of AXM -995 OMR [2]: Table 5: General Technical Information Operation Temperature: Relative Operation humidity Storage Temperature Relative storage humidity Voltage Network Filter Power Consumption +10 to +35 degrees centigrade 20% to 80% without condensation -10 to +50 degrees centigrade 5% to 9 % 50/60HZ 115V/230V (10%) Delta EMI interference filter. 100VA
Table 6: Electrical Characteristics Microprocessor RAM Program memory RAM data memory Saving to Ram Motor Interface 80c85 CMOS 32KB for interpretative routine 32KB. 3V (Lt-In) Stepper Motor 3Nos. Serial V24/RS 232C.
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Table 7: Mechanical Characteristics Capacity of the input lift Capacity of the output trays Speed of document transport Paper weight Paper dimension Tray management ~ 550 documents (for 90gm/m2 ) Refused =~70 documents Accepted= ~400 documents (for 90gm/m2 ) 14 m/s or about 7200 doc. A4/h 80 to 160 g/m2 86 54 mm (minimum) 305 229 mm (maximum) Controlled by the program Table 8: Dimensions of the Machine Length: Width Depth Weight: 715mm 435 mm 390 mm 35 Kg. Table 9: Printer Characteristics Type of Head Character set Max. number of Chars. Per doc. Printing Speed 9 needle matrix Alphanumeric. 120 Characters. 40 cm per second.
Table 10: Replacement parts list: Transport wheel Separation Wheel Separation rubber kit Mini pitch belt 475 and 390 Feeding belt Fuse 1.6A and 3.15 A Data cable DB 25 female / male Adapter DB9 fem/DB 25 male Ink ribbon LC9 13 1 1 2 1 2 1 1 1
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4.3 Disposition of the parts of AXM-995 OMR:
1. Selector Switch 2. Start Button 3. Sixteen Character display unit 4. Separation Button 5. Feed Tray 6. Adjuster of document width 7. Selector of document width 8.Refused Tray 9. Adjuster of false document tray. 10.Output Tray 11. Hinged Cover including the printer option 12. Selection zone of True and False document 13.Optical Reading Head
Figure 2: AXM-995 OMR (Front End)
1. Main Power Switch 2. General Fuse 3. Power Plug 4. Parallel Plug 5. Serial Connector
Figure 3: AXM-995 OMR (Back End)
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1. LB. A Controls if there are documents in the input tray for automatic feeding 2. LB. B Detects a document before it passes under the read head 3. LB. C Controls the document transport and detects if the lower output tray is full. The reader display will indicate GOOD TRAY FULL. 4. LB. D Controls the document transport and detects if the upper ejection tray is full. The reader display will indicate BAD TRAY FULL.
Figure 4: AXM-995 OMR (Light Barrier Sensors)
The Optical Mark Reader AXM 995 is an automatic device with a motorized feeding tray and two output trays for the document. Its conception provided easy use and access to documents and requires little maintenance. Its high transportation speed and the unique feeding system make it a particularly secure and efficient device. Its programming possibilities make it flexible, user friendly and easy to integrate into any data system.
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4.4 Application of Optical Mark Reader: There are different types of OMR machines. Optical Mark Reading (OMR) technology is to process larger volumes of information faster and with greater accuracy. They eliminate the need for manual data entry and collection by processing thousands of documents an hour, automatically. Whats more, the variety of forms our scanners can accommodate is almost limitless. Listed above are just some of the many applications our scanners are used for. The small footprint, lightweight yet durable design and versatility of the OMR make it an ideal device for a wide variety of data gathering applications: Retail Counters: Points of sale, Workstations Medical applications: Doctor orders, lab reports, patient visits, health risk appraisal Education: Test scoring, multiple-choice examination forms Game: Gaming windows, betting houses Lottery, survey, ballot processing, voting booths, polling centers Kiosks and other remote locations, when coupled with a laptop computer, etc. Staffing/Employment: Job Knowledge Tests, EEOC and Civil Service Tests, Employment Applications, Drug Testing and Tests, Employee Record Keeping, Benefits and Compensation: Time and Attendance (Payroll) ,COBRA ,Enrollment and Change Forms, Benefit Evaluation Forms, United Way , Tuition Assistance, Stock Purchase/401(k) Options Health and Safety: Safety Training/Testing, Hazardous, OSHA Compliance, Communication Training, Response Forms, Health Risk Appraisals Training and Development: Skills Assessment Forms, Certification Testing, Opinion and Organizational, Instructor Evaluation Surveys, Course Enrollment, Technical Training Programs, and Attendance.
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4.5 Disposition of the OMR forms used in EBCC: 4 3

1. Timing Mark 2. Page Head 3. Bullet Mark 4. Litho Codes
1 Figure 5: H-type form
The above OMR form is known as H-Type form in EBCC.
The HEX code of 31
characters, 1 character of Board identity, 3 character of Subject code, 4 character of Examiner Code, 4 character of answer script serial, 1 character of answer script extra paper identity, 3 character of mark identity, 3 character of Head examiner mark identity data is to collected from the form. The data file also given the identity of bullet mark. The bullet mark represent from feed accurately or not. 3 4
1. Timing Mark 2. Page Head 3. Bullet Mark 4. Litho Codes
2 1 Figure 6: E-type form The above OMR form is known as E-Type form in EBCC. The HEX code of 31
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characters, 1 character of Board identity, 1 character of Examination identity, 3 character of Subject code, 6 character of Student Roll No., 6 characters of Student Registration No. data is to be collected from the form. The data file also given the identity of bullet mark. The bullet mark represent from feed accurately or not. This two from are matching by HEX Code. This is a double headed form. By
this form a Student all information for registration of S.S.C & H.S.C are
collected. In Name (40 Characters) ,
Student Examination Board (1 Character),
Passing Year ,Roll No.& Registration
No. (6 Characters) respectively, and
similar data which mention in the
figure is collected.
Figure 7: SIF-type form (top side)
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Figure 8: SIF-type form (bottom side) This is back portion of the previous form. The mention list data are collected from the sheet. Data accuracy also be collected by Bullet Marks. This can be feed by the OMR machine by any way, but the programming language can be represented the data in sequence.
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Figure 9: M Type OMR form
This form knows as M -Type OMR in EBCC. This type OMR form is widely used in various types of recruitment examination. The form is designed based on the other forms using the, Timing Mark, Page Head, Bullet Mark etc. In EBCC, this form is used only in S.S.C examination.
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Figure 10: P Type OMR form Several types of from are used in EBCC for different categories of data collection. To design a new from and to read by machine is possible in form Timing mark & page Head are designed in the same manner.
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4.6 Data Processing System in EBCC: Data collection procedure and result publication procedure of Education Boards of Bangladesh is done by EBCC. The entire procedures are shown by the following flow chart diagram: ---
OMR form fill up by the student
Send the OMR form to EBCC
Shorting Sorting Humidifying the OMR forms
Scanning the OMR forms Scanning False Data Making Primary Database
Solve the database Manually Checked Data Making Secondary Database
Making Final Database
Tabulate the database Decoding Result Figure 11: Flow chat of Data Processing system in EBCC.
The operation of EBCC is started when the OMR form is going on hand to the students. The students first fill up the forms according to their respective information. The
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schools, colleges or examination centers authority collected the OMR forms and make the packet. The respective authority then send these document to EBCC for taking further action. The computer centre team then collected the all documents, which are coming to their address from all corners of the country. The first stage of data processing of EBCC is called shorting. In this stage operator of EBCC is open the packet of OMR forms as well as the make a record both a hard copy and a soft copy of the OMR forms. In the document the identity of the OMR forms, i.e. numbers of forms with the schools, colleges or examination centers is recorded. As the forms mainly arrival to EBCC by postal department it takes few days for delivery. However, the forms are thin and packed a two or more thousand lots; so that was untidy. These types of forms are making disturb while given to OMR machine for feeding. To rectify these problems the lots of OMR forms are passing through a hot air flow by the humidifier machine. The third and the vital stage of data processing is the scanning. Our case study mainly based on this stage. In this stage, the forms are feed by OMR machine. The information of the OMR forms is recorded as text document by machine and its related software through data cable. The documents then converted as database information. From this data, error and true data are marking separate. The true data are taking for further procedure. The false data are sending to previous stage once for checking more consciously. Later the information is repeated for previous action and after that, which was doing the further procedure with the true data. Finally, all the data are proceeding for final action. When the finished data is generated, the data is transferred for validation. In the validation, stage each student all data are checked by means of all hidden codes by software. In addition, the final data is captured as database in the format of Hexadecimal number. Later the data is used for preparing the tabulation. From the tabulated data, the result is prepared. Before the result all, the data is stored in different database file in Hexadecimal code. In addition, the respective files are keeping very in secret by password. Only the chief executive of the respective education boards is the authority to use the password. This stage is known as decoding in EBCC.
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4.7 Scanning System in EBCC: Before time we mention the major task in EBCC is the scanning section. We choose this section as our case study. The entire scanning system is shown in the following: Sort out OMR From
PC
OMR
Switch on PC & OMR Software Loading in OMR machine
Enter File Name
Preparation for data scanning Manually ADD OMR form Press Start Button of OMR Start another file Start Scanning OMR Sheet False OMR Sheet/Machine Stop
Data Storage in PC
Stop the Program
Stop the Process Figure 12: Flowchart of scanning system.
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The entire scanning system by OMR machines shows in above figure 9. The files are created in the from text file with an extension of (X SUB T NUM.doc). Here, X first character of respective education board, SUB subject code of the script, T script category, NUM number of the file created. Each file contains 1000 / 1200 (One thousand / One Thousand two hundred) sheets of data or very near to the same. A bundle has more or less five to six examination center/ Examiners a single or multiple lots. Each files document are recoding in a summarized method that is know as tag (Figure 10) in EBCC. If any queries of any sheets are come for checking, the tag paper works as the hard copy of the data. Therefore, tag paper is an important hardcopy document when the total data is prepared. In early hours, we mention a bundle has more or less five to six examination center/ Examiners a single or multiple lots; that is for searching a single sheet from a huge group of OMR forms. Different logic programs use to purify the data. That is mention in next chapter 4. The authority of center / Examiners mention the OMR forms information in a prescribed format, along to the bundle. All this information is sequentially written down in tag sheets (figure 13).
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Board of Intermediate and Secondary Education, DA/RJHI/JSR/CMA/SLY/CTG SSC/HSC Examination, 200X File Name : X/ ### /$/ ### Serial No. Centre /Head Examiner Code Total Sheets in the Bundle Ending Sheet Roll/ Serial No. Cum. Count of the sheet Actual Total Repeat Counting Reject Number of Document D/C
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
OMR Machine No.
Solve Date:
OMR Operator & Date:
Backup Date
Figure 13 : A Tag sheet used in EBCC
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4.8 Optical Mark Reader (OMR) - Problems and Errors: There are different problems and errors are showing while operating OMR machine. Those errors are stopping the machine. Therefore, the machine operator should have a deep look on the machine while it is running. On the time while error messages are displayed ones should first remove errors of the machine and then again restarting the machine. The common problems and errors are following: Sheets not accepted
There may be many reasons why sheets are not accepted by the OMR machine. If the OMR forms are crumpled, in any way, the machine may give an error message and the operator of the machine may need to restart the machine by removing the particular problem. When sheets are not accepted by the OMR, the following error message may shows in the display unit of AXM -995 OMR. Bad Feeding: After three consecutive feedings of OMR sheet when the next OMR form has still not arrived under light barrier LB B (2nd no. sensor) of the machine, the mention error message showing in the display unit. The machine operators then replace the first document (s) on the lift and press the start button of the OMR machine. Jam Before head: The OMR form has reached on the light barrier LB B, but not the OMR read head, the mention error message showing in the display unit. The machine operators then remove the document having caused the paper jam. This document has not been read correctly and should be put into tray of refused documents or back on the lift (input tray of OMR) and press the start button of the OMR machine. Jam Under head: The beginning of the OMR form has been detected by the OMR read head, but its end has not been seen within a lap of one second of the documents appearance under the head, the mention error message showing in the display unit. The machine operators then remove the document having caused the paper jam. This document has not been read correctly and should be put into tray of refused documents or back on the lift (input tray of OMR) and press the start button of the OMR machine. Paper Press: While the document is not detected on the input lift in test mode, the mention error message showing in the display unit. The machine operators then replaced
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new document on to the input tray of the machine and press the start button of the OMR machine.
Operating Error
There may be many reasons while OMR forms are available on the input tray of machine but the running OMR machine is stopping. Those problems of AXM -995 OMR is following: Bad Tray full: The OMR machine has two trays one called good tray and the next one is bad tray. In the continuous form has been detected by the OMR read head, but its end has not been seen within a lap of one second of the documents appearance under the head, the mention error message showing in the display unit. The machine operators then remove the document having caused the paper jam. This document has not been read correctly and should be put into tray of refused documents or back on the lift (input tray of OMR) and press the start button of the OMR machine. Good Tray full: While the machine is continuously operating but the read OMR form, fulfill the good tray i.e. there is not enough space to accepted next document must be ejected, the mention error message showing in the display unit. Also if the light barrier LB C (3rd sensor) is obstructed by any means then the machine also stopping displaying this error message. All documents of the good tray should be removed and press the start button of the reader.
Unidentified sheet
If a MCQ form/sheet is fed in upside down or back to front as well as the OMR form definition does not compare with the load software of the AXM-995 then this error will be displayed on the PC.
Length error
There may be many grounds while OMR forms are available on the input tray of machine but the running OMR machine is stopping. Those problems of AXM -995 OMR is following:
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Sheet too short: The last transported OMR document in the machine is 6.25% shorter than the reference document (usually the first document of a stack). Remove the document having caused the error and press the start button of the reader to make the machine restart. Sheet too thin: The AXM-995 has a capability to read the 80 gms paper. The OMR sheet which is now entering is more than 25% too thin. Remove the document having caused the error and press the start button of the reader. Sheet too thick: The OMR sheet, which is now entering, is more than 50% too thick. Remove the document having caused the error and press the start button of the reader Sheet too long: The last transported document is 6.25% longer than the reference document (usually the first document of a stack).Remove the document having caused the error and press the start button of the reader.
Miscellaneous Error:
There are also some identified problems but those occur very few in the life period. Some problem permanently stopping the machine and some may takes many to time to restart the system. Those are being mentioned below: Low Battery: The OMR motherboard battery of machine is empty and must be changed to restarting the machine. Bad Retention: The memory retention of the OMR is faulty; the battery could be defect. Reload firmware and the application program of the machine to restart. Path Not Free: Two documents are transported too closely to each other to the machine. Remove the second document and press the start button on the reader. The removed document has not been read. No Black Gauging: The black reference of the synchronization (clock) mark sensor varies. If the message returns after the reader has been switched off call on the maintenance service.
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No Decoder: If during the READ of OMR form or in BARCODE test the barcode option is not there or defect, the reader will display NO DECODER. Firstly installed the barcode software and restart the machine. Probl Bac Appel: The input tray (lift) could not move up. Make sure nothing blocks the movements of the input tray and press the start button. If the message returns call the maintenance service. Good Tray Error: The tray of accepted documents could not move up. Make sure nothing blocks the movements of the tray and press the start button. If the message reappears, call the customer service. Security Stop: The security of the input tray (lift) is activated. Remove the fingers or documents from the input tray and press the start button. If the message reappears, call the maintenance service. No Sheet in Good: The OMR form, which should be ejected to the tray of good OMR forms, did not arrive Look for the document in the tray of refused OMR forms. This OMR form has been read correctly. Press the start button to start the machine. No Sheet In Bad: The OMR form, which should be ejected to the tray of refused OMR form, did not arrive look for the document in the tray of accepted OMR forms. Press the start button to start the machine.
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Chapter-5: Fault Analysis: Case Study

5.1 Introduction: Data collection and processing of the true data is the main job of EBCC. In the case of entire processing of S.S.C / H.S.C examination result is completed by 60 (sixty)/ 65 (sixty-five) working days. Total system of the result processing is already shown in Figure 8. The entire system has dependent on four sections: Sorting Scanning Validation Decoding.
The major job of EBCC is done by scanning sections and the job is based on OMR machine. Besides first two sections are working more or less simultaneously and required about 45 (forty-five) to 50 (fifty) working days to complete. Moreover, the rest two sections complete the final job within the rest stipulated time. Therefore, in case of EBCC we use TPM for improvement the entire result processing system. We give a deep observation on the OMR machine scanning system for better time management. In addition, we are applying WWBLA as analytical instrument. 5.2 Functions of TPM: A great amount of organizations finds, that in spite of the huge improvements in the productivity in the last years, there is still a big potential to be better in utilizing the machine tools and in reaching the better productivity goals. Like the Japanese say, To discover the mountain of possibilities . One main method to meet this challenge is the TPM. TPM is a systematic approach to understanding the equipment's function, the equipment's relationship to product quality and the likely cause and frequency of failure of the critical equipment components. According to Japanese scientist Nakajima and Suzuki, A formal definition and concept is given by:
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1. TPM is aimed at maximizing equipment effectiveness through the optimization of equipment availability, performances, efficiency and product quality. 2. TPM establishes a maintenance strategy (level and type of PM, productive maintenance) for the life of the equipment. 3. TPM covers all departments such as the planning department, the users and the maintenance department. 4. TPM involves all staff members from top management down to shop floor workers. 5. TPM promotes improved maintenance through small group autonomous
activities. 5.3 The Advantages of TPM: A systematic and long - term work with the TPM has an influence especially on the following elements in any organisation Productivity is improving through fewer losses in the company Quality is also been improved as a result, that the failures and malfunctions are reduced and the order and method are focused The Costs are lower, because the losses, and other not value generating work are reduced The Delivery Times can be kept better, because the production without disturbances is easier to plan Environment and Security is better, because leakages are tightened. Motivation is higher, because the responsibility and rights are delegated and the investment in the personal is done, in the form of education.
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Total Available Time on Equipment
Six Big Losses
Overall Equipment Effectiveness
Capabilities
Competitive Factors
Delivery Equipment Failure Down Time Losses Availability Setup and Adjustment Idling & Minor Stoppage Speed Losses Reduced Speed Performance Efficiency First Changeover Capability Decreased Lead Time Flexibility
Reduced Buffer Inventory Increased Effective Capacity
Cost
Defects in Process Defect Losses Reduced Yield Rate of Quality Products
Less Scarp and rework
Quality
Figure 14: Impact of maintenance on competitiveness
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5.3.1 TPM - TQM (Total Quality Management) Many Similarities: The TPM program closely resembles the popular Total Quality Management (TQM) program. Many of the tools such as employee empowerment, benchmarking, documentation etc. used in TQM are used to implement and optimize TPM. The final goal is to deliver a product, which is filling all the quality requirements of the customer, and that all the costs can be predicted. It can be said, that the maintenance and the quality are two different features of the same issue. So, that the maintenance is long - termed quality control. The maintenance is concentrating on the machine, processes and slow trends; meanwhile the quality control is dealing with tools, wear - off and the management of fast changes. Table 11: Similarities and difference between TQM and TPM Category Objective Means goal Target of TQM Quality(output and effects) TPM Equipment (input and cause)
attaining Systemize the management. It is Employees participation and it is software oriented Quality for PPM hardware oriented Elimination of losses and wastes
5.4 Generalized Losses of a manufacturing organisation: One of the major goals of TPM and OEE programs is to reduce and /or eliminate the losses of what are called the Six Big Losses the most common causes of efficiency loss in any manufacturing or simply any organisation which have a job on similar to production. The following table lists the six big losses, and shows how they relate to the OEE loss categories.
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Table 12: Generalized Losses of a manufacturing organisation Six Big Loss Category Breakdowns OEE loss Category Down time loss Event Examples Tooling failures Unplanned maintenance General Breakdowns Equipment failure Setup and adjustments Down time loss Setup/changeover Material shortages Operator shortages Major adjustments Warm-up time Small stops Speed loss Obstructed product flow Component jams Misfeeds Sensor blocked Delivery blocked Cleaning/checking Reduced speed Speed loss Rough running Under nameplate capacity under design capacity equipment wear operator inefficiency Startup rejects Quality loss Scrap Rework In-process damage In-process expiration Incorrect assembly Production Rejects Quality loss Scrap Rework In-process damage In-process expiration Incorrect assembly Rejects during steady-state production. Rejects during warm-up, startup or other early production. May be due to improper setup, warm-up period, etc. Anything that keeps the process from running at its theoretical maximum speed (a.k.a. Ideal run rate or nameplate capacity). Typically only includes stops that are under five minutes and that do not require maintenance personnel Comment There is flexibility on where to set the threshold between a breakdown (down time loss) and a small stop (speed loss). This loss is often addressed through setup time reduction programs.
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5.4.1 Addressing the Six Big Losses: The six big losses are and some of the events that contribute to these losses, we can focus on ways to monitor and correct them. Categorizing data makes loss analysis much easier, and a key goal should be fast and efficient data collection, with data put to use throughout the day and in real-time. Breakdowns:
Eliminating unplanned down time of any plant is essential to improving OEE. Other OEE factors cannot be addressed if the process is down. It is not only important to know how much down time your process is experiencing (and when) but also to be able to attribute the lost time to the specific source or reason for the loss (tabulated through reason codes). With down time and reason code data tabulated, root cause analysis is applied starting with the most severe loss categories. Setup and adjustments:
Setup and adjustment time is generally measured as the time between the last good parts produced before setup to the first consistent good parts produced after setup. This often includes substantial adjustment and/or warm-up time in order to consistently produce parts that meet quality standards. Tracking setup time is critical to reducing this loss, together with an active program to reduce this time (such as an SMED - single minute exchange of dies program). Many companies use creative methods of reducing setup time including assembling changeover carts with all tools and supplies necessary for the changeover in one place, pinned or marked settings so that coarse adjustments are no longer necessary, and use of prefabricated setup gauges. Small stops and reduced speed:
Small stops and reduced speed are the most difficult of the six big losses to monitor and record. Cycle time analysis should be utilized to pinpoint these loss types. In most processes, recording data for cycle time analysis needs to be automated since cycles are quick and repetitive events that do not leave adequate time for manual data logging. By comparing all completed cycles to the ideal cycle time and filtering the data through a
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small stop threshold and reduced speed threshold the errant cycles can be automatically categorized for analysis. The reason for analyzing small stops separately from reduced speed is that the root causes are typically very different, as can be seen from the event examples in the previous table. Startup rejects and production rejects:
Startup rejects and production rejects are differentiated, since often, the root causes are different between startup and steady state production. Parts that require rework of any kind should be considered rejects. Tracking when rejects occur during a shift and/or job run can help pinpoint potential causes, and in many cases, patterns will be discovered. Often a six sigma program, where a common metric is achieving a defect rate of less than 3.4 defects per million "opportunities", is used to focus attention on a goal of achieving "near perfect" quality. 5.5 Importance of Overall Equipment Effectiveness: Many organizations that recognize the important roll equipment and process performance have on bottom line results are turning to the measure, which drives TPM called Overall Equipment Effectiveness (OEE), which incorporate not only availability but also performance Rate and Quality Rate. In other words, OEE addresses all losses caused by the equipment: not being available when needed due to breakdowns or setup and adjustment losses; not running at the optimum rate due to reduced speed or idling and minor stoppage losses; and not producing first A1 quality output due to defects and rework or start up losses. A key objective of TPM is to cost effectively maximize Overall Equipment Effectiveness through the elimination or minimization of all losses. A simple model outlining these losses is shown in figure 15. When many organizations first measure OEE it is not uncommon to find they are only achieving around 40 %-60% (batch) or 50%- 75% (continuous process) whereas the international best practice figure is recognized to be +85% (batch) and 95% (continuous process) for Overall Equipment Effectiveness. In effect, this means there exists in most companies the opportunity to increase capacity/productivity by 25%-100%. TPM significantly reduces operational and maintenance costs by focusing on the root cause of failure through the creation of a sense of ownership by the plant & equipment operators, maintainers and support staff to encourage prevention at source. To understand the
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thinking behind TPM we need to investigate what causes failure. Most of the concept of the root cause of failure and the too used to assist in the search for the root cause WWBLA.
5.5.1 OEE Factors: OEE factor denotes the plant's efficiency and effectiveness as well as the overview of productivity losses that occur in the typical manufacturing environment. Therefore, the OEE calculation starts with plant operating time and end up at fully productive time, showing the sources of productivity loss that occur in between the entire process. The Six Big Losses describes the most common causes for efficiency loss usually found in today's manufacturing environment. Six root causes of loss are presented, each directly related to an OEE Factor. Here we have given detail concept of measuring the OEE of any organisation.
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Six Big Losses Break down Availability Setup and Adjustment Reduce Speed Performance Rate Idling and Minor Stoppage
Target
Zero
Minimize
Overall Equipment Effectiveness
Zero
Zero
Defects and Rework Quality Rate Startup
Zero
Minimize
Figure 15: Overall Equipment Effectiveness Model
Plant Operating Time: The Plant Operating Time is the subtraction of the category of time called Planned
Shut Down to actual operating time; which includes all events that should be excluded from efficiency analysis because there was no intention of running production (e.g. breaks, lunch, scheduled maintenance, or periods where there is nothing to produce). The remaining available time is your Planned Production Time.
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Planned Production Time (Shut down Time): OEE begins with Planned Production Time and scrutinizes efficiency and
productivity losses that occur, with the goal of reducing or eliminating these losses. There are three general categories of loss to consider. Such as i) ii) iii) Down Time Loss, Speed Loss and Quality Loss.
Availability takes into account Down Time Loss, which includes any Events that stop planned production for an appreciable length of time (usually several minutes - long enough to log as a track able Event). Examples include equipment failures, material shortages, and changeover time. Changeover time is included in OEE analysis, since it is a form of down time. While it may not be possible to eliminate changeover time, in most cases it can be reduced. The remaining available time is called Operating Time.
Operating Time (Down Time Loss): Performance takes into account Speed Loss, which includes any factors that cause
the process to operate at less than the maximum possible speed, when running. Examples include machine wear, substandard materials, misfeeds, and operator inefficiency. The remaining available time is called Net Operating Time. Net Operating Time: Quality takes into account Quality Loss, which accounts for produced pieces that do not meet quality standards, including pieces that require rework. The remaining time is called Fully Productive Time. Our goal is to maximize Fully Productive Time. Here we now give a look how the factors that contribute to OEE Losses are developed we can quickly review the key points.
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Table 13: Overall Equipment Efficiency Factor Loss Planned Shutdown Down Time Loss OEE Factor Not part of the OEE calculation. Availability is the ratio of Operating Time to Planned Production Time (Operating Time is Planned Production Time less Down Time Loss). Calculated as the ratio of Operating Time to Planed Production Time.
-
100% Availability means the process has been running without any recorded stops.
Speed Loss
Performance is the ratio of Net Operating Time to Operating Time (Net Operating Time is Operating Time less Speed Loss).
Calculated as the ratio of Ideal Cycle Time to Actual Cycle Time, or alternately the ratio of Actual Run Rate to Ideal Run Rate.
100% Performance means the process has been consistently running at its theoretical maximum speed.
Quality Loss -
Quality is the ratio of Fully Productive Time to Net Operating Time (Fully Productive Time is Net Operating Time less Quality Loss). Calculated as the ratio of Good Pieces to Total Pieces. 100% Quality means there have been no reject or rework pieces.
World Class OEE:
OEE is essentially the ratio of Fully Productive Time to Planned Production Time (refer to the OEE Factors section for graphic representation). In practice, however, OEE is calculated as the product of its three contributing factors: OEE = Availability x Performance x Quality
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This type of calculation makes OEE a severe test. For example, if all three contributing factors were 90.0%, the OEE would be 72.9%. In practice, the generally accepted excellent goals for each factor are quite different from each other, as is shown in the table below. Table 14: Representation World Class OEE Factor
OEE Factor
World Class
Availability Performance Quality Overall OEE
90.00% 95.00% 99.90% 85.00%
Worldwide studies indicate that the average OEE rate in manufacturing plants is 60%. However, a World Class OEE is considered to be 85% or better. 5.5.2 Calculating OEE: As early, we described the OEE calculation is based on the three OEE Factors: Availability, Performance, and Quality. Now here is given the procedure how each of these factors is calculated. Availability Availability takes into account Down Time Loss, and is calculated as: Availability = Operating Time / Planned Production Time Performance Performance takes into account Speed Loss, and is calculated as: Performance = Ideal Cycle Time / (Operating Time / Total Pieces)
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Ideal Cycle Time is the minimum cycle time that your process can be expected to achieve in optimal circumstances. It is sometimes called Design Cycle Time, Theoretical Cycle Time or Nameplate Capacity. Since Run Rate is the reciprocal of Cycle Time, Performance can also be calculated as: Performance = (Total Pieces / Operating Time) / Ideal Run Rate Performance is capped at 100%, to ensure that if an error is made in specifying the Ideal Cycle Time or Ideal Run Rate the effect on OEE will be limited. Quality Quality takes into account Quality Loss, and is calculated as: Quality = Good Pieces / Total Pieces And finally the OEE OEE takes into account all three OEE Factors, and is calculated as: OEE = Availability x Performance x Quality
5.6 Identification the fault process of OMR scanning system: The OMR machine stops for different causes. For this reason, the data collection time is required more. Our case study is to identification the major fault in scanning system as well as to minimize the period of stopping OMR machines by means the improvement of the Overall Equipment Efficiency (OEE). Over the past 30 years, Japanese have studied and practiced what they term Total Quality Control (TQC). One of the leaders in this movement has been Kaoru Ishikawa. Ishikawa and others repeatedly point to fact that Japanese industrial workers are among the worlds finest in their level of education and quantitative skills. Consequently, one of the critical features of the Japanese approach to quality control is its focus on quantitative methods on the factory floor.
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Based on his experience in Japanese industry, Ishikawa states that as much as 95 percent of quality related problems in the factory can be solved with seven fundamental quantitative tools, also termed the seven old tools. Those are: a) Cause Effect diagram b) Stratification analysis c) Check Sheet d) Histogram e) Scatter diagram f) Pareto analysis g) Control charts. In this study, I took the two tools. Check Sheet and Pareto analysis to identify the major problem of the OMR scanning system in EBCC. 5.6.1 Check Sheet: A check sheet is a simple tools used to record and classify observed data. There are two types of check sheets (a) Pictorial and (b) tabular. Of the two different types, we use a pictorial check sheet that shows in figure 16 & 17. The designed of the two check sheets based on our demand as our case fault identification according OMR machine history. One sheet is to count the no of time the fault occurs and the other sheet is to calculate the time to rectify the problems.
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Tag : Problem Check Sheet Machine No. 13831 Date: 14/05/06 Start Time: 12.15 p.m. End Time: 12.34 p.m. Error
Bad Feeding (BF) Jam Before Head (JBH) Jam Under Head (JUH) Sheet too Thick (Stk) Sheet too Thin (Stn) Sheet too long (Stl) Good Tray Full (GF) Bad Tray Full (Btf) Path Not Free(Pnf) Security Stop (SS) Lift Error (LE) Jam in Sorting (JIS) Waiting Request (WR) SOS test fail(SOS) Paper Press (PP) Bad Retention (BR) Other (OT) |||| |||| |||| | | ||| | |||| |||| ||||
Operator Name: Md. Habibur Rahman Script Type: H Total Script: 1100 Comments: Test Check No. of Time(s) Occurred Total
1 15
14
Figure 16: Check sheet use for counting the No. of Time(s) the fault Occurred
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Tag : Problem Check Sheet Machine No. Date: Start Time: End Time: Error
Bad Feeding (BF) Jam Before Head (JBH) Jam Under Head (JUH) Sheet too Thick (Stk) Sheet too Thin (Stn) Sheet too long (Stl) Good Tray Full (GF) Bad Tray Full (Btf) Path Not Free(Pnf) Security Stop (SS) Lift Error (LE) Jam in Sorting (JIS) Waiting Request (WR) SOS test fail(SOS) Paper Press (PP) Bad Retention (BR) Other (OT) 2 2 2 1 # 1 3
Operator Name: Script Type: Total Script: Comments: Total Stopping Time (in Min.) Total Time
1 3
# Time required less than 1(one) minute. Figure 17: Check sheet use for counting the Total Stopping Time (in Min.) of the OMR.
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After studying all the sections of EBCC, the scanning sections were taken for the case project purpose. Then all the scanning operators are informed about the case study according to the TPM four steps policy. Three operators fill up the check sheet for fifteen days in two sessions. From the check sheet, we summarized two categories of data for our study purpose (Table 15). These figures denote the no times the OMR machines stops during the case study period as well as represents the time the OMR machines shut down for process operation. Table 15: Period & Phase the OMR machine stop in study period. Losses ( Causes of Machine Shut down ) Bad Feeding (BF) Jam Before Head (JBH) Jam Under Head(JUH) Sheet Too Thick(Stk) Sheet Too Thin(Stn) Sheet Too Long(Stl) Good Tray Full(GF) Bad Tray Full (Btf) Path Not Free(PNF) Security Stop (SS) Lift Error(LE) Waiting Request (WR) SOS Fault(SOS) Paper Press(PP)+Tag preparation +Bundle Packet Bad Retention(BR) No. of times Fault occurs 1486 2642 178 141 91 448 11 8 30 2 2 2 0 1280 0 Shut down period (in minute)
22 27 12 2 1 13 1 0 1 0 5 0 0 100 0
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5.6 Analytical Techniques of Fault analysis: Every organisation sets a preventing method of failure before it makes any harm. There are several proactive tools, technique and quality method enables the identification and prevention of process or product errors before they occur. The common analytical techniques used in TPM for improvement a process is following [7] : i)WWBLA ii) P-M analysis iii) Why Why analysis iv) Fault tree analysis v) Failure Mode Effect analysis vi)Pereto analysis vii)SPC etc. 5.6.1 Pareto Analysis: In nineteenth century Italy, the Italian economist Vilferdo Pareto observed that about 80 percent of the countrys wealth was controlled by about 20 percent of the population. This observation leads to what is now known as the Pareto Principle; it is also known as 80-20 rule. Popular scientist Juran and Gary applied this concept to the causes of quality failures. They stated that 20 percent of the causes account for 80 percent failures. In general, the Pareto Principle, applied to quality, suggests that he majority of the quality losses are maldistributed in such a way that a vital few quality defects or problems always constitute a high percent of the overall quality losses (but not in strictly an 80-20 relationship) The intent of a Pareto analysis is to separate that vital few from the trivial many. Thus, the Pareto analysis can assist us to identify the most important effects and causes and to stratify the available data so that we can prioritize our products process improvement efforts. In general, we see two types of Pareto diagrams: (1) result-category diagrams and (2) cause-category diagrams. Results diagrams focus on the classification and relative importance of observable results (e.g., product defect categories such as scratches, dents). Cause diagrams focus on the classification and relative importance of detected causes (e.g., process related categories such as a dull cutting tool, a misaligned die).
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5.6.4 Cause Effect and Pareto Integration: Pareto analysis and Cause effect analysis are useful in all product life cycle phases: definition, design, development, production, delivery, sales and service, usage and disposal. They are systematic, through and based on simple logic. The Pareto diagrams quantitative structure allows us to stratify and prioritize our information (management by fact). The qualitative structure of the cause effect diagram allows us to capture experience, engineering, judgment and reasonable technical speculation in our results. Pareto diagrams and cause effect diagrams analysis are frequently used together in developing effective pro actions or corrective reactions since each provides different yet necessary information to support the analysis. Typically, we use a Pareto analysis and the resulting diagram to identify a critical problem or opportunity for quality improvement. Then, we use the cause effect analysis and diagram to identify causes relative to the effect. The Pareto diagram helps determine the effect we select for the focus of CE analysis. The cause effect diagram then displays all possible causes of a quality problem or challenge and aids in identifying root causes. When the two diagrams are used together, they become an instrument for documenting and communicating quality improvement progress as well as for gaining perspectives on problem solving during the quality improvement process.
5.6.5 Identification the significant Losses in OMR scanning System: To identify losses and equipment efficiency of OMR scanning system in EBCC we choose eight OMR machines for 6 days during operation. The data is representing in Table 15 based on CE diagram. From these six (6) major losses, the most significant losses are then identified by Pareto analysis.
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Table 16 : Pareto Chart for Six major Losses in OMR Scanning System Major Losses Paper Press (PP) Jam Before Head (JBH) Bad Feeding (BF) Jam Under Head(JUH) Sheet Too Long (Stl) Lift Error (LE) Total Time (minutes) 120 29 25 14 14 5 207 %Composition 58 14 12 7 7 2 100 Cumulative % 58 72 84 91 98 100
The diagram is given below:
Pareto Chart for six major losses

140 120 100 Time 80 60 40 20 0
Paper Press (PP) Jam Before Head (JBH) Bad Feeding (BF) Jam Under Head(JUH) Sheet Too Long(Stl) Lift Error(LE)
120 Cumulative % 100 80 60 40 20 0
Figure 18:
Pareto Chart for six major losses
Therefore, by Pareto chart it is seen that the most significant sources of OEE losses are Paper Press, Jam before Head and Bad Feeding of the OMR scanning system.
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5.7 Calculating OEE for OMR: We know, OEE= Availability x Performance x Quality. Again, Availability = Operating Time / Planned Production Time Performance = Ideal Cycle Time / (Operating Time / Total Pieces) Or, Performance = (Total Pieces / Operating Time) / Ideal Run Rate Quality = Good Pieces / Total Pieces. Here A, Running time per day =60 Minutes *7hrs=420 Minutes B, Down time per day=30 minutes C, Loading time per day=A-B=420-30=390 minutes D, Stoppage losses per day=207/7=30 minutes E, Operating time per day=C-D=390-30=360 minutes F, Output per day = 2572 sheets G, Rate of Quality Products= (Processed amounts- Defect amount)/ Processed amounts*100 = (126000-5000)/126000*100=96.03% [Defect amount =Error data/ Error Sheet] H, Idle Cycle Time *=6 seconds =0.10 minutes I, Actual Cycle time** =7 seconds=0.12 minutes J, Actual Processing time^ =I*F=0.12*2572=309 minutes K, Operating speed rate=H/I*100= (0.1/0.12)*100=83.33% L, Net Operating rate=J/E*100=309/360*100=85.83% M, Availability= (E/C)*100= (360/390)*100=92.30%
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N, Performance efficiency=K*L*100=0.8333*0.8583*100=71.52%
* Ideally a machine read 50 sheets per minute ** Actually a machine read 40 sheets per minute ^ Per hour per machine output sheets= (126000/7)/7=2571.43, So, OEE=M*N*G*100 =0.9230*0.7152*0.9603*100 =63.39%. 5.7.1 Factors influence OEE in OMR Scanning System: From the Pareto chart six major fault breakdowns it is seen that the most significant sources of OEE losses are Paper Press, Jam before Head and Bad Feeding of the OMR scanning system. Early we mentioned that we use WWBLA to make out the subdivision of major causes that break off the OMR scanning system efficiency. From the case report, it is easily recognize that Paper Press is the vital issue of machine stopping. In the case study, it is seen that the AXM -995 OMR trays can accepts 500 sheets at a time. Due to the post phase, scanning system software in EBCC maximum 250 nos. sheet / OMR form with four (4) slots read in one interval for few subjects. Moreover, most of the subjects OMR form scan with 100 nos. forms with 10 or max 15 bundles. The operator records data in tag form as well as the bundle is packing according to direction of EBCC. The properties of OMR machine gives use an idea that 30 sheets can read by the OMR machine in a minute. In practical, we see this is idle case. Students have not adequate knowledge about the OMR form uses, therefore, the handle the OMR with negligence. The unsafe carrying system of the OMR from far distance of the country, Students negligence as well as the paper quality may the dent OMR form that causes occasionally stopping the OMR machine in the fault name Jam before Head, Bad Feeding etc. These causes of stopping OMR scanning system can call Idling and Minor Stoppage. However, Idling and Minor Stoppage of the scanning system is the combination of Paper Press (Tag preparation + Bundle packing), Jam before Head, Bad Feeding. It can be easily observed from the following Pareto analysis.
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Table 17: Major Causes of machine stoppages
Major Losses Tag preparation Bundle packing Jam Before Head Bad Feeding Total
Time (minutes) 49 36 29 25 139
%Composition 35 26 21 18 100
Cumulative % 35 61 82 100
From Figure 20, it is seen that the main cause of Idling and minor stoppage is Tag preparation, Bundle packing, Jam before Head, Bad Feeding. Now WWBLA technique is used for identifying the counter measures to reduce the problems.
5.7.2 The Stages of WWBLA: Early we mention that in this study we used WWBLA techniques to identify the root cause and then segment the root cause to solve the problem. A Why Why Because Logical Analysis (WWBLA) starts with gathering information about the incident (Figure 15). This information is then used to construct either a List of Facts (facts listed alone) or a Why Why-Because Logical List. When the first factor is identified then it is marked as G. Here G means Go. The facts then divided into second factor for problem is identified and verified. In this way, a third, fourth problems are identified. And so on. When the factors are not segment to any factor, then it is marked as NG (stands for No Go). Finally, countermeasures are identified for each root cause or facts of problem.
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The entire process of WWBLA is factored into eight sub processes, Such that: i) ii) iii) iv) v) vi) vii) viii) Gather Information (Root cause identification) Determine the Facts ( Segmentation of the root cause) Create a List of Facts ( create a list of related cause/problem of the process) Create a Why Because Logical List Create an Auxiliary List of Facts Determine the Mishap / Top Node Determine the Necessary Causal Factors Quality Assurance and Correction of the WB Graph (Countermeasures identified).
The total system can be represented by the following flow chart:
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Incident occurred
Gather Information (GI)
Determine Facts (DI)
No
Use list of facts Create WWBLA
Yes Create list of Facts (CL) No

Create Auxiliary List of Facts (CA) Clear picture of Course of events / Participants?
Yes
Determine Mishap / Top node (DM)
Determine Necessary casual factors
Assure Quality (AQ)
Correct WB-Graph
Create report
Finished
Figure 19: WWBLA Overview
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In this study, we use check sheet to get information from the history of the OMR scanning system in EBCC. As well as we used Pareto analysis to identified the major losses in the total process. Here we used WWBLA to find out the segmentation the main cause and to go its last stage for find the countermeasures. Here, each fault, which interrupts the process, is known as facts and its division is known as Auxiliary facts. The division of those facts is to identify the mishap and to set finalized countermeasures. Each fact and consequently the auxiliary facts are verified whether it can be divided into further root causes. If it is possible, then it is marked as G. Here, G stands for Go. Then a second factor for problem is identified is verified. In this way, a third, fourth problems are identified. If it is not possible to identify further, then verification is marked as NG (Stand for No Go). Finally, countermeasures are identified for each causes of problem.
Pareto Chart for major causes of machine stoppage

60 50 40
Time
120 100 Cumulative % 80 60 40 20 0

Tag preparation Bundle packing Jam Before Head Bad Feeding
30 20 10 0
Figure 20: Pareto Chart for major causes of machine stoppage
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Table 18: Why Why Because Logical Analysis (WWBLA) worksheet. Countermeasures 1.1.1. Tag should make from raw data using software. 2.1.1 Placed New OMR form / Smooth the twisted form and again placed the form. 3.1.1 Smooth the sheet or shuffling the sheets before placed in the machine input tray. 4.1.2 Change Transport wheel the 4.1.2 Change Separation wheel. 2nd Factor for Problem 3rd Factor for problem 1st Factor for problem
Verification
Verification
1. Machine input tray is empty 2. OMR machine is wait for paper 3. OMR machine cannot take the form 4. Machine is tried to take form but failed.
1.1 Machine Operator is Busy
1.1.1 Operator is preparing Tag 2.1.1 Last OMR form is twisted / folding. 3.1.1 Two or more sheet is going to be feed 4.1.1 Machine yet not takes the form.
NG
2.1 OMR form is not placed accurately in the machine input tray. 3.1 Sheet thickness is not accurate
NG
NG
Paper Press
4.1 Adjust the Head of machine
NG.
Verification
Problem
the
5. OMR form quality is poor
NG
5. Better quality of form should be used.
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5.8 Results: From the WWBLA worksheet, we found five segmentations against the paper press fault in the OMR scanning System. Due to countermeasures found in the WWBLA, the stoppage loss per day reduced to 30 minute to 26 minutes and consequently per machine OMR form reading capacity almost increases from 2572 sheets to 3000 sheets in an hour. According to the equation of OEE it is seen that if the countermeasures are taken the losses per day can be reduced and hence OEE is increased which is shown below: OEE= Availability x Performance x Quality. Again, Availability = Operating Time / Planned Production Time Performance = Ideal Cycle Time / (Operating Time / Total Pieces) Or, Performance = (Total Pieces / Operating Time) / Ideal Run Rate Quality = Good Pieces / Total Pieces. Here A, Running time per day =60 Minutes *7hrs=420 Minutes B, Down time per day=20 minutes C, Loading time per day=A-B=420-20=400 minutes D, Stoppage losses per day=180/7=26 minutes E, Operating time per day=C-D=400-26=374 minutes F, Output per day = 3000 sheets G, Rate of Quality Products= (Processed amounts- Defect amount)/ Processed amounts*100 = (142000-4500)/142000*100=96.83% [Defect amount =Error data/ Error Sheet] H, Idle Cycle Time *=6 seconds =0.10 minutes
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I, Actual Cycle time** =7 seconds=0.12 minutes J, Actual Processing time^ =I*F=0.12*3000=360 minutes K, Operating speed rate=H/I*100= (0.1/0.12)*100=83.33% L, Net Operating rate=J/E*100=360/374*100=96.18% M, Availability= (E/C)*100= (374/400)*100=93.57% N, Performance efficiency=K*L*100=0.8333*0.9618*100=80.15%
^ Per hour per machine output sheets= (141850/7)/6=3000, So, OEE=M*N*G*100 =0.9357*0.8015*0.9683*100
=72.62%.
Prior to apply WWBLA techniques we get OEE 63.39 %.
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Chapter 6: Conclusion & Recommendation

In the project work, it scrutinize that the two significant causes of losses that decreases the efficiency of OMR machine, which Paper Press and Jam before head / Bad are feeding. Of theses losses, the most significant loss Paper Press is considered for reducing and thereby maximizing equipment efficiency. By WWBLA techniques, we found five sections of the problems. We choose better OMR form, designed a sort program against tag writing and used new separation and transport wheel, during the case session. On this way, the OMR represent 9.23 % more efficient. Improve the OMR machines OEE can improve as high as 85% or even more which is standard for Japanese industries, if the entire root causes of significant losses are reducing. EBCC may not think this matter earlier times i.e. because they have a loose schedule time during this study period. However, this year GOB takes a policy to publish the result of S.S.C and H.S.C examination within 60 (sixty) days. In this year to meet, the schedule EBCC uses the machine more time. However, if they take the report as their drug we are hopeful they can complete their job in the normal office time. From the study, it is found that the concept of TPM can be applied to any industry successfully. Today, with competition in industry at all time high, TPM may be one of the tools that stand between success and total failure for some companies. It has been proven a program that works. It can be adapted to work not only in industrial plants, but also in construction, building maintenance, transportation and in variety of other situations like EBCC. Employees must be educated and convinced that TPM is not just another program of the month and that management is totally committed to the program and the extended period necessary for full implementation. If everyone involve in a TPM program does his or her part, and unusually high rate of return compare to resources invested may be expected. In the case study, it has been found that OEE has increased 72.62% from 63.39% while a single problem was consider and analyzed by only one tool of TPM (WWBLA). Here, it can also be mentioned that only one cause of the mentioned single problem has been considered. Thus from the research work it can be concluded that the OEE could be increased as high as to 85 %( which is a Japanese Bench Mark) if we consider all the
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problems and solve those by several analytical tools of TPM. Therefore, overall performance of OMR machine can be improved by implementing TPM to EBCC for meeting more jobs in a sort period in future.
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REFERENCES 1. 2. (www.education board .gov. bd.) on 8.10.2007 Scantron Corporation, 1361 Valencia Avenue Tustin CA 92680, USA, User manual AXM 995 OMR, April 1995. 3. Richard B. Chase, F. Robert Jacobs, Nicholas J. Aquilano, Operation Management For Competitive Advantage, Tata McGraw-Hill Publishing Company Ltd, New Delhi, 10th Edition 2004. 4. Venkatesh J, (www. plant maintenance.com) An introduction to Total Productive maintenance (TPM), The palnt Maintenance Resource Centre, Oct, 2005. Japan Institute for Plant Maintenance, on 4.4.2007 5. (www.wem.nu/oee.html) OEE: Overall Equipment Efficiency, OEE index & Calculation. 6. A practical Guide to Why Because Logical Analysis Method, Thilo Paul- Stuve, September 21, 2005. 7. Creation of quality- Fundamental Strategic and Tactical Quality Tools, AIT, Thailand.
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Improving The Equipment Efficiecy (OMR Machine-A Case of Education Board Computer Centre, Dhaka, Bangladesh

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Master of Advanced Engineering Management

Improvement in Equipment Efficiency: Case of Education Board Computer Centre

By SYED MD. SHAEEDUZZAMAN

Syed Md. Shaeeduzzaman

Chapter 2: Literature Review

OEE = Equipment availability x Performance Efficiency Rate of Quality Products

Chapter-3: Education Boards & EBCC

System Analyst Programmer

Asst. Main. Engr.

Figure 1: Organization Chart of EBCC

Table 1: Scanning and related picture of EBCC in S.S.C Examination 2007

Board Dhaka Rajshahi Comilla Jessore Barisal Sylhet Chittagong Madrasha

Female Student 107889 93320 35636 47546 23360 14570 28583

1980115 33654 Total Examinee 7,23,514

Total Script/OMR from Scanned 2,60,46,497

Table 2 : Scanning and related picture of EBCC in H.S.C Examination 2008

Female Student 71926 62213 23757 31697 15573 9713 19055

Chapter-4: Optical Mark Reader (OMR): Scanning System

4.3 Disposition of the parts of AXM-995 OMR:

Figure 2: AXM-995 OMR (Front End)

Figure 3: AXM-995 OMR (Back End)

Figure 4: AXM-995 OMR (Light Barrier Sensors)

4.5 Disposition of the OMR forms used in EBCC: 4 3

1 Figure 5: H-type form

The above OMR form is known as H-Type form in EBCC.

The HEX code of 31

collected. In Name (40 Characters) ,

Student Examination Board (1 Character),

Passing Year ,Roll No.& Registration

No. (6 Characters) respectively, and

similar data which mention in the

Figure 7: SIF-type form (top side)

Figure 9: M Type OMR form

OMR form fill up by the student

Send the OMR form to EBCC

Shorting Sorting Humidifying the OMR forms

Solve the database Manually Checked Data Making Secondary Database

Making Final Database

Switch on PC & OMR Software Loading in OMR machine

Enter File Name

Stop the Program

Stop the Process Figure 12: Flowchart of scanning system.

OMR Machine No.

OMR Operator & Date:

Figure 13 : A Tag sheet used in EBCC

Chapter-5: Fault Analysis: Case Study

Total Available Time on Equipment

Six Big Losses

Overall Equipment Effectiveness

Reduced Buffer Inventory Increased Effective Capacity

Defects in Process Defect Losses Reduced Yield Rate of Quality Products

Less Scarp and rework

Figure 14: Impact of maintenance on competitiveness

Overall Equipment Effectiveness

Defects and Rework Quality Rate Startup

Figure 15: Overall Equipment Effectiveness Model

World Class OEE:

Availability Performance Quality Overall OEE

90.00% 95.00% 99.90% 85.00%

The diagram is given below:

Pareto Chart for six major losses