Dynamic trip point categorisation using manufacturing process for polycrystalline diamond compact bits as case study

Disruptions in the manufacturing process cast substantial impacts on the consumer's centric values, cost, and overall efficiency. The ripple effect of these disruptions is observed in the whole assembly line. The proper analysis and mitigation of disruptions is the key to the proficiency of the plant and resource utilisation. The research focuses on the quantitative analysis of the impact of disruptions of the manufacturing process, which is performed by analysing the disruptive workstation dynamically. The disruptive workstations have a significant impact on succeeding and preceding workstations, which have been analysed dynamically, and accordingly, the pre-set alarm trip points are elevated. The results show that lowering the number of starts and stops decreases the number of rejections of valuable process batches that finally improve efficiency. Finally, the developed model is implemented on a polycrystalline diamond compact drill bit manufacturing plant. The results are compared with the research work of other researchers, showing a 60% reduction in the number of start/stop events, 60% reduction in downtime, while a 75% reduction in the number of rejections is noted.