Systematization, implementation and analysis of the overall throughput effectiveness calculation for the finishing processes after weaving

Abstract

For the sustainability of continuous improvement, the importance of acquiring as much data as possible from the production field is indisputable. However, converting these data into key performance indicators in a lean production system is much more important. This paper focuses on the finishing processes of the weaving industry in a real production plant. In the study, roll of fabric based traceability is first provided by a radio frequency identification (RFID) and programmable logic controller (PLC) automation structure. In the next step, the calculation of the overall equipment effectiveness (OEE) for each process is provided, and a method of converting these OEE values to the unique indicator as the overall throughput effectiveness (OTE) is proposed. In the last phase of the paper, after getting OTE value automatically, it was aimed to reveal the relationship between the production environment parameters and the OTE indicator. A revised hybrid genetic algorithm was proposed to determine the most important production environment parameters that affect OTE results. Multiple linear regression was utilized to verify the result of the developed algorithm.