Companies consistently strive for increased productivity to maintain competitiveness in today's advanced world. This has led the need for a well-defined performance evaluation system for manufacturing processes. This paper outlines the study, development, and implementation of a structured framework to measure efficiency and productivity for a European company in the premium packaging industry for perfumery and cosmetics. Additionally, it explains the design and establishment of a system for analysis, monitoring, and the identification of process inefficiencies to facilitate the implementation of continuous improvement projects. A comprehensive exploration of various methods available in the literature for measuring productivity in manufacturing processes is initially executed. These approaches are categorized into four groups based on [1] classification proposal: Operation Research-based methods, System analysis-based methods, Continuous improvement methods, and Metrics-based methods. Each category is defined, explained, and evaluated to ascertain its suitability for the objectives of this project. Ultimately, the Overall Equipment Effectiveness (OEE) is selected as the most appropriate methodology, given company's context and the scope of this project. OEE serves as a performance evaluation tool that not only delivers an aggregate value but also offers insights into the specific areas where efficiency losses occur, thus uncovering opportunities for process improvement. Moreover, with the goal of enhancing communication and comprehension across various organizational levels, diverse alternatives for monitoring and controlling the obtained output are assessed, in order to offer more robust and comprehensive visualizations of OEE on manufacturing equipment. Business intelligence software is chosen for crafting the dashboards to be showcased, given its ability to provide comprehensive performance management solutions. Furthermore, distinct visuals are strategically delineated, highlighting various elements evaluated in OEE arranged to different user categories. During the implementation phase, numerous challenges emerged concerning the reliability of the collected information, attributed to the existing data handling and management procedures. Consequently, an exhaustive process of data analysis and cleaning was undertaken to rectify identified issues within the database. An overall data reliability level of 82.5% was achieved. Cases with inaccuracies were excluded from the calculations to ensure the derivation of reliable insights. The faulty ones were pointed out for individual analysis and subsequent correction. Results obtained revealed the existence of a gap for improvement in terms of availability, performance, and quality, especially when benchmarked against [2]'s recommended international standards. The developed dashboards facilitated the identification of process weaknesses, enabling an elaborated assessment for the implementation of improvement projects. Therefore, a set of well-structured actions were executed to enhance the company's efficiency, and further proposals for implementation were delineated, acknowledging those that fell beyond the immediate scope of this project. The devised performance management system, based on the OEE measurement framework, effectively fulfilled the expectations of the focal company. It offered a robust instrument for measuring, assessing, and monitoring performance obtained, specifying the reasons behind production losses through dynamic graphical representations accessible to all organizational levels. Thus, providing insight into the challenges impacting the manufacturing process at both a comprehensive and detailed level.
Le aziende si sforzano costantemente di aumentare la produttività per mantenere la competitività nel mondo avanzato di oggi. Ciò ha portato alla necessità di un sistema di valutazione delle prestazioni ben definito per i processi produttivi. Il presente documento illustra lo studio, lo sviluppo e l'implementazione di un quadro strutturato per misurare l'efficienza e la produttività di un'azienda europea che opera nel settore del packaging di alta qualità per la profumeria e la cosmesi. Inoltre, illustra la progettazione e la creazione di un sistema di analisi, monitoraggio e identificazione delle inefficienze di processo per facilitare l'implementazione di progetti di miglioramento continuo. Inizialmente viene eseguita un'esplorazione completa dei vari metodi disponibili in letteratura per la misurazione della produttività nei processi produttivi. Questi approcci vengono classificati in quattro gruppi sulla base della proposta di classificazione di [1]: Metodi basati sulla ricerca operativa (Operation Research-based methods), Metodi basati sull'analisi di sistema (System analysis-based methods), Metodi di miglioramento continuo (Continuous improvement methods), e Metodi basati sulla metrica (Metrics-based methods). Ogni categoria viene definita, spiegata e valutata per verificarne l'idoneità agli obiettivi di questo progetto. Alla fine, l'Overall Equipment Effectiveness (OEE) è stata selezionata come la metodologia più appropriata, dato il contesto aziendale e l'ambito di questo progetto. L'OEE è uno strumento di valutazione delle prestazioni che non solo fornisce un valore aggregato, ma offre anche indicazioni sulle aree specifiche in cui si verificano le perdite di efficienza, scoprendo così le opportunità di miglioramento dei processi. Inoltre, con l'obiettivo di migliorare la comunicazione e la comprensione tra i vari livelli organizzativi, vengono valutate diverse alternative per il monitoraggio e il controllo dell'output ottenuto, al fine di offrire visualizzazioni più robuste e complete dell'OEE sulle apparecchiature di produzione. Per la creazione dei cruscotti da presentare è stato scelto un software di business intelligence, grazie alla sua capacità di fornire soluzioni complete per la gestione delle prestazioni. Inoltre, sono stati delineati strategicamente dei visual distinti, che evidenziano i vari elementi valutati nell'OEE, organizzati per diverse categorie di utenti. Durante la fase di implementazione, sono emerse numerose sfide relative all'affidabilità delle informazioni raccolte, attribuite alle procedure di gestione e trattamento dei dati esistenti. Di conseguenza, è stato intrapreso un processo esaustivo di analisi e pulizia dei dati per correggere i problemi identificati all'interno del database. È stato raggiunto un livello complessivo di affidabilità dei dati dell'82,5%. I casi che presentavano imprecisioni sono stati esclusi dai calcoli per garantire l'elaborazione di dati affidabili. Quelli difettosi sono stati segnalati per un'analisi individuale e una successiva correzione. I risultati ottenuti hanno rivelato l'esistenza di un gap da migliorare in termini di disponibilità, prestazioni e qualità, soprattutto se confrontati con gli standard internazionali raccomandati da [2]. I cruscotti sviluppati hanno facilitato l'identificazione delle debolezze del processo, consentendo una valutazione elaborata per l'implementazione di progetti di miglioramento. Pertanto, sono state eseguite una serie di azioni ben strutturate per migliorare l'efficienza dell'azienda e sono state delineate ulteriori proposte di implementazione, riconoscendo quelle che esulavano dall'ambito immediato di questo progetto. Il sistema di gestione delle prestazioni ideato, basato sul quadro di misurazione dell'OEE, ha soddisfatto efficacemente le aspettative dell'azienda target. Ha offerto uno strumento solido per misurare, valutare e monitorare le prestazioni ottenute, specificando le ragioni delle perdite di produzione attraverso rappresentazioni grafiche dinamiche accessibili a tutti i livelli organizzativi. In questo modo, ha fornito una visione delle sfide che impattano sul processo produttivo sia a livello globale che dettagliato.
Improving operational efficiency: a comprehensive study, design, and implementation of a performance management system in a cosmetic premium packaging company
Quintero Ardila, Daniel David
2022/2023
Abstract
Companies consistently strive for increased productivity to maintain competitiveness in today's advanced world. This has led the need for a well-defined performance evaluation system for manufacturing processes. This paper outlines the study, development, and implementation of a structured framework to measure efficiency and productivity for a European company in the premium packaging industry for perfumery and cosmetics. Additionally, it explains the design and establishment of a system for analysis, monitoring, and the identification of process inefficiencies to facilitate the implementation of continuous improvement projects. A comprehensive exploration of various methods available in the literature for measuring productivity in manufacturing processes is initially executed. These approaches are categorized into four groups based on [1] classification proposal: Operation Research-based methods, System analysis-based methods, Continuous improvement methods, and Metrics-based methods. Each category is defined, explained, and evaluated to ascertain its suitability for the objectives of this project. Ultimately, the Overall Equipment Effectiveness (OEE) is selected as the most appropriate methodology, given company's context and the scope of this project. OEE serves as a performance evaluation tool that not only delivers an aggregate value but also offers insights into the specific areas where efficiency losses occur, thus uncovering opportunities for process improvement. Moreover, with the goal of enhancing communication and comprehension across various organizational levels, diverse alternatives for monitoring and controlling the obtained output are assessed, in order to offer more robust and comprehensive visualizations of OEE on manufacturing equipment. Business intelligence software is chosen for crafting the dashboards to be showcased, given its ability to provide comprehensive performance management solutions. Furthermore, distinct visuals are strategically delineated, highlighting various elements evaluated in OEE arranged to different user categories. During the implementation phase, numerous challenges emerged concerning the reliability of the collected information, attributed to the existing data handling and management procedures. Consequently, an exhaustive process of data analysis and cleaning was undertaken to rectify identified issues within the database. An overall data reliability level of 82.5% was achieved. Cases with inaccuracies were excluded from the calculations to ensure the derivation of reliable insights. The faulty ones were pointed out for individual analysis and subsequent correction. Results obtained revealed the existence of a gap for improvement in terms of availability, performance, and quality, especially when benchmarked against [2]'s recommended international standards. The developed dashboards facilitated the identification of process weaknesses, enabling an elaborated assessment for the implementation of improvement projects. Therefore, a set of well-structured actions were executed to enhance the company's efficiency, and further proposals for implementation were delineated, acknowledging those that fell beyond the immediate scope of this project. The devised performance management system, based on the OEE measurement framework, effectively fulfilled the expectations of the focal company. It offered a robust instrument for measuring, assessing, and monitoring performance obtained, specifying the reasons behind production losses through dynamic graphical representations accessible to all organizational levels. Thus, providing insight into the challenges impacting the manufacturing process at both a comprehensive and detailed level.| File | Dimensione | Formato | |
|---|---|---|---|
|
Final Thesis - Daniel Quintero.pdf
non accessibile
Descrizione: Improving Operational Efficiency: A Comprehensive Study, Design, and Implementation of a Performance Management System in a Cosmetic Premium Packaging Company.
Dimensione
3.83 MB
Formato
Adobe PDF
|
3.83 MB | Adobe PDF | Visualizza/Apri |
I documenti in POLITesi sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
https://hdl.handle.net/10589/214651