Reduction of Non Added Value Activities During Machine Breakdown to Increase Overall Equipment Efficiency

Lean manufacturing has been introduced into many industries to increase productivity through reduction of waste. Downtime is one of the contributing factors in determining the production availability time. Changeover time and breakdown failures affect the production available time and this is the main concern in all the manufacturing industries. In this paper, a case study in an electronics assembly line was done to identify the availability time of the operating surface mount technology machine. Reduction in changeover time increased the availability time from the total planned time that leads to increment of overall equipment efficiency from 83.43 to 84.06%. The increment of availability time has increased the performance and overall equipment efficiency from 81.64 to 82.84% and from 64.71 to 66.15% respectively. The increment of overall equipment efficiency increased the production output by 2180 units/month which increased the financial capacity by 545000 MYR/month. The proposed techniques can be used as benchmark to determine the operational decisions made by managements of any manufacturing companies especially in electronics assembly.