NIK AFIEZA BINTI CHE AZHAR. Thesis submitted in fulfilment of the requirements for the award of the degree of Master of Sciences (by Research)

Transcription

1 DEVELOPMENT OF A... '-'-..., J. n.ud ni.:,.t vv v~ u1-u A ENVELOPMENT ANALYSIS (DEA) MODEL TO ANALYZE PRODUCTION LINE'S PERFORMANCE: COMBINATION OF AUTOMATION AND LABOR NIK AFIEZA BINTI CHE AZHAR Thesis submitted in fulfilment of the requirements for the award of the degree of Master of Sciences (by Research) Faculty of Technology UNIVERSITI MALAYSIA P AHANG OCTOBER 2016

2 TABLE OF CONTENTS Page DECLARATION TITLE PAGE DEDICATION 11 ACKNOWLEDGEMENTS 111 ABSTRAK iv ABSTRACT v TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS VI x XI Xll Xlll CHAPTERl INTRODUCTION 1.1 Introduction to the Research Research Question Problem Statement Objectives Research Approach Scope of the Dissertation Thesis Overview 9 CHAPTER2 LITERATURE REVIEW 2.1 Performance Measurement Quality and Productivity Improvement Data Envelopment Analysis Two-Stage Network DEA Network System in Recent DEA Literature DEA Chames-Cooper-Rhodes (CCR) Model 21

3 DEA Window Analysis The Concept of Production Efficiency (Structure of Loss) Large losses of Efficient Inhibition of Human Efficient Inhibition of Semi-Automation Efficient Inhibition of Fully Automation Major Losses of Equipment CHAPTER3 METHODOLOGY Research Procedure Phase I - Information Collection Surfing the internet Books and writing materials Discussion with supervisor and staff at M technologies Phase 2 - Data Collection Phase 3 - Deciding DMUs Phase 4 - Developing Two-Stage Network DEA Model System Planning Stage System Design Stage Measuring Performance Phase 5 - Recommendations CHAPTER4 MODEL DESIGN 4.1 Introduction 4.2 Development of Two-Stage Network DEA Model Stage I: Evaluation Performance of Productivity Stage 2: Evaluation of Quality of Product in Terms of Cost and Time in Production Line 4.2 Conclusion CHAPTERS RESULT AND DISCUSSION 5.1 Result 51

4 Stage 1: Evaluation Performance of Productivity Stage 2: Evaluation of Quality of Product in Terms of Cost and Time in Production Line Discussion and Conclusion CHAPTER6 CONCLUSION AND FUTURE WORK Conclusion Future Work REFERENCES APPENDICES 64 Al Sample of Raw Data Production Line Model A (Month 1) - Stage 1 A2 Sample of Raw Data Production Line Model B (Month 1) - Stage 1 A3 Sample of Raw Data Production Line Model C (Month 1) - Stage 1 A4 Sample Of Raw Data Production Line Model D (Month 1) - Stage 1 A5 Sample of Raw Data Production Line Model E (Month 1) - Stage 1 Bl Sample of Raw Data Production Line Model A (Month 1) - Stage 2 B2 Sample of Raw Data Production Line Model B (Month 1) - Stage 2 B3 Sample of Raw Data Production Line Model C (Month 1) - Stage 2 B4 Sample of Raw Data Production Line Model D (Month 1) - Stage 2 B5 Sample of Raw Data Production Line Model E (Month 1) - Stage 2 Cl Sample of Calculation Input And Output Data In Stagc, 1 C2 Sample of Calculation Input And Output Data In Stage 2 Dl Sample of Evaluation Data Using DEA-Solver Stage 1 D2 Sample of Evaluation Data Using DEA-Solver Stage

5 E Production Line's Layout 95

6 LIST OF TABLES Table No. Title Page 2.1 Example of window analysis Result of calculation for window analysis Table Inputs and outputs data to evaluate productivity Score of production lines productivity for window Average score and rank of production line productivity Input and output data to evaluate losses due to time and cost Score of production lines total losses Average score and rank of total losses due to tiine and cost Relationship between 8 1 and

7 LIST OF FIGURE Figure No. Title Page 2.1 The Process Quality Improvement Two-Stage process of DMUj Series production system Parallel production system DEA model Window analysis model The relationship of 7 equipment major loss and OEE Framework of Research Procedure Step of Data Collection Production Lines Flow Chart Process flowchart Network DEA Model for Production Line Performance DEA-Solver software Introduction to DEA-Solver Page Model Selection Page Window-I-C Page Data Sheet Selection Page File Name Page Run the Data Page Exit Page (Last Page) Variation through window 1 for stage Variation through window 1 for stage 2 59

8 LIST OF SYMBOLS e Efficiency

9 LIST OF ABBREVIATIONS CCR DEA DMU EFQM KPI ROI Charnes-Cooper-Rhodes Data Envelopment Analysis Decision Making Units European Foundation for Quality Management Key Performance Indicator Return on Investment