A New Techno-Economic Real-Time Total Process Performance Indicator

Journal of Optimization in Industrial Engineering

دوره 15، شماره 2 - شماره پیاپی 33، آذر 2022، صفحه 265-281   

نوع مقاله: Original Manuscript

شناسه دیجیتال (DOI): 10.22094/joie.2022.1956163.1951

نویسندگان

Mohamed K Hassan^* ؛ Islam Emara

Arab Academy for Science, Technology and Maritime Transport, PO Box 1029, Alexandria 21913, Egypt

چکیده

Process performance measurement is a significant and crucial activity carried out by organizations aiming at controlling their processes. Most of the traditional performance indicators do not include important factors such as the effects of the external constraints on the process and do not emphasize the economic aspects influencing an organization. An organization’s performance evaluation should measure both its efficiency and effectiveness, and not one or the other. The newly developed Total Process Performance (TPP) indicator is an integrated indicator that takes into account the process efficiency and effectiveness. This study modifies and integrates the efficiency and effectiveness of original formulae to create -for the first time- a customized new formula that includes important techno-economic factors representing a holistic overview of the process/organization performance. The study developed two indicators, a High (H) frequency indicator (early alarm), TPP|_H which is calculated on hourly bases and intended for use by the floor managers, and a Low (L) frequency indicator, TPP|_L that can be calculated for a longer period and intended to be used by top management. TPP|_H reflects the shop floor’s real-time performance based on internal factors, while TPP|_L reflects the company performance based on internal and external factors. The differences between the newly developed indicators and the traditional indicators are illustrated. A real-time performance monitoring system is also developed. A case study for applying the new indicators in an iron-making plant is introduced.

کلیدواژه‌ها

Process performance measurement؛ effectiveness؛ efficiency؛ real-time indicators

مراجع

Aditya, P. (2007), “Study and Analysis of Maintenance Performance Indicators (MPIs) for LKAB: A Case Study”, Journal of Quality in Maintenance Engineering, Vol. 13, No. 4, pp. 325–337.

Ahuja, I., and Khamba, J. (2008), “Total Productive Maintenance: Literature Review and Directions”, International Journal of Quality and Reliability Management, Vol. 25, No. 7, pp. 709–756.

Al-Shaiba, A., Al-Ghamdi, S., and Koc, M. (2019), “Comparative Review and Analysis of Organizational (In)Efficiency Indicators in Qatar”, Sustainability, Vol. 11, No. 23, p. 6566.

Alsyouf, I. (2006), “Measuring Maintenance Performance Using a Balanced Scorecard Approach”, Journal of Quality in Maintenance Engineering, Vol. 12, No. 2, pp. 133–149.

Antosz, K. and Stadnicka, D. (2014), “Evaluation Measures of Machine Operation Effectiveness in Large Enterprises: Study Results”, Eksploatacja I Niezawodnosc, Vol. 17, No. 1, pp. 107–117.

Azizi, A. (2015), “Evaluation Improvement of Production Productivity Performance Using Statistical Process Control, Overall Equipment Efficiency, and Autonomous Maintenance”, Procedia Manufacturing, Vol. 2, pp. 186–190.

BEM, Business Enterprise Mapping (2021), "How to Measure Total Process Efficiency", available at: https://www.businessmapping.com/blog/total-process-efficiency/ (accessed 24 December 2021).

Ben-Daya, M. (2009), Handbook of Maintenance Management and Engineering, Springer-Verlag London Limited, London.

Berhan, E., Yibeltal, S. and Geremew, S. (2018), “Service Performance Improvement Model: The Case of Teklehaymanot General Hospital”, Journal of Optimization in Industrial Engineering, Vol. (11), No. (1), pp. 23-33.

BS EN 15341 (2019), “Maintenance Key Performance Indicators”, ISBN 978 0 580 97964 4.

CIQA Validation Engineering (2021), “What is effectiveness versus efficiency according to process excellence”, available at: https://ciqa.net/what-is-effectiveness-versus-efficiency-according-to-lean-six-sigma/ (accessed 20 December 2021).

Enste, U. and Gmbh, L. (2017), “Successful Resource Efficiency Indicators for Process Industries Step-by-Step Guide Book”, VTT Technology, Finland.

Fabbri, R., P., Aningi, H., and Muni, K. V. (2019), “OEE optimization of an assembly line through lean and TPM methodologies, International Journal of Manufacturing Research, Vol. 6, No. 6, pp. 388-393.

Gackowiec, P., Podobińska-Staniec, M., Brzychczy, E., and Özver, T. (2020), “Review of Key Performance Indicators for Process Monitoring in the Mining Industry, Energies, Vol. 13, No. 19, p. 5169. DOI: 10.3390/en13195169.

Ivancic, I. (1998), “Development of maintenance in modern production”, Euromaintenance '98: proceedings; 14th European Maintenance Conference, 5-7 October 1998, Dubrovnik, Croatia, in HDO - Hrvatsko Drustvo Odrzavatelja.

Muchiri, P., and Pintelon, L. (2008), “Performance Measurement Using Overall Equipment Effectiveness (OEE): Literature Review and Practical Application Discussion, International Journal of Production Research, Vol. 46, No. 13, pp. 3517–3535.

Muchiri, P., Pintelon, L., Gelders, L., and Martin, H. (2011), “Development of maintenance function performance measurement framework and indicators”, International Journal of Production Economics, Vol. 131, No. 1, pp. 295-302.

Nakajima, S. (1998), “Introduction to Total Productive Maintenance (TPM)”, Cambridge: Productivity Press.

Neely, A., Gregory, M., and Platts, K. (2005), “Performance Measurement System Design: A Literature Review and Research Agenda”, International Journal of Operations and Production Management, Vol. 25, No. 12, pp. 1228–1263.

Nonthaleerak, P. and Hendry, L. (2006), “Six Sigma: Literature Review and Key Future Research Areas”, International Journal of Six Sigma and Competitive Advantage, Vol. 2, No. 2, pp. 105–161.

OEE, Overall Equipment Effectiveness (2021), available at: “ https://www.oee.com/”,  (accessed 20 December 2021).

Pollalis, Y., A., and Ioannis G., K. (2013), “Enterprise Performance Measurement: Using the Balanced Scorecard for Business Optimization”, Journal of Applied Systems Studies, Vol. 4, No. 3, pp. 1–32.

Raouf, A. (1994), “Improving Capital Productivity Through Maintenance”, International Journal of Operations and Production Management, Vol. 14, No. 7, pp. 44-52.

Scott, D. and Pisa, R. (1998), “Can overall factory effectiveness prolong Moore's law?”, Solid-state technology, Vol. 41, No. 3, pp. 75-82.

SMRP (2020). Society for Maintenance and Reliability Professionals Best Practice Metrics SMRP Best Practice Metrics Series, 6^th edition.

Stenström, C., Aditya P., Kumar, U., and Galar, D. (2013), “Performance Indicators and Terminology for Value-Driven Maintenance”, Journal of Quality in Maintenance Engineering, Vol. 19, No. 3, pp. 222–232.

Tsarouhas, P. (2019), “Improving Operation of the Croissant Production Line through Overall Equipment Effectiveness (OEE): A Case Study”, International Journal of Productivity and Performance Management, Vol. 68, No. 1, pp. 88–108.

Urban, W. (2017), “Amoeba Management System Transformation in the Light of Organisational Change Literature”, Management and Production Engineering Review, Vol. 8, No. 1, pp. 16–23.

Vaezi, E. (2021), “Measuring the performances of Medical Diagnostic Laboratories based on interval efficiencies”, Journal of Optimization in Industrial Engineering, Vol. (14), No. (2), pp. 137-154.

Van Looy, A., and Shafagatova, A. (2016), “Business Process Performance Measurement: A Structured Literature Review of Indicators, Measures, and Metrics”, SpringerPlus, Vol. 5, No. 1, pp. 1–24.

Viveros, G., P. (2018), “Graphical Analysis for Overall Effectiveness Management: A Graphical Method to Support Operation and Maintenance Performance Assessment”,  Quality and Reliability Engineering International, Vol. 34, No. 8, pp. 1615–1632.

Yemane, A. M., Heniey, H. A. and Gebrehiwet, K. G. (2021), “Performance Measurement and Improvement of Healthcare Service Using Discrete Event Simulation in Bahir Dar Clinic”, Journal of Optimization in Industrial Engineering, Vol. (14), No. (2), pp. 41-51.