Purpose – The purpose of this paper is to show the implementation of a maintenance management model based on total productive maintenance (TPM) in a production line of a metallurgical company, with high-precision equipment requiring effective maintenance to maintain the quality of the production process. Design/methodology/approach – Has been proposed a model for conducting the activities, emphasizing the training activities of the teams involved in the implementation, collection and analysis of industrial performance indicators from a year before the implementation of TPM. The development followed the timetable of activities and the results of these performance indicators were collected again after the application of the model. Findings – It observed that after the implementation of TPM, and the results of these performance indicators were collected again after the application of the model. Thus, it is concluded that the TPM assists in improving industrial performance and competitiveness of the production line studied. Originality/value – The angle, from which the paper approaches the TPM problem, is original for the studied company and shows positives results. It allows the company to apply the model in their others production lines and factories to achieve an improvement in industrial performance and competitiveness.
Abstract:In Brazil, companies work primarily with preventive and predictive maintenance (BRAZILIAN…, 2009). The maintenance sector has been strategic for companies to achieve results efficiently and with planned costs. However, the maintenance indicators are not usually analyzed. The purpose of this study was to analyze the maintenance performance of a metallurgical company and to identify potential maintenance indicators that may be adopted by that enterprise. Thus, it is expected that the maintenance sector be more competitive and efficient, contributing to the achievement of results. In order to do so, data and time periods of maintenance, nature of maintenance, and service plan for preventive maintenance were collected from the company's control system for the time period of one year. After that, the data were catalogued onto a spreadsheet. Then, the suggested indicators that were relevant to the availability of equipment for production as well as to the percentage of hours worked in preventive/predictive maintenance compared to corrective maintenance were analyzed. Preliminary results showed that the programming methodology adopted for maintenance in this study improved the availability of equipment for production and also the time of corrective maintenance, which it is of great importance.
This paper presents a case study fulfilled at the maintenance sector of a metallurgical company. The research problem addressed was the satisfactions level of customers of the maintenance. The objective was to quantify the performance of preventive and corrective maintenance, mechanical and electrical, in relation to customer satisfaction. To achieve this aim, we conducted an applied research, quantitative, developed by a case study. With the knowledge of some theoretical models of performance measurement, we adopted the Key Performance Indicators-KPI-as the most suitable method for measuring proposal. With this, it developed questionnaires to assess the satisfaction of the performance of maintenance. After the data collection, spreadsheets were created to quantify the answers to the questionnaires. The results of this study present the responses to the seven requirements that assess the satisfaction of preventive maintenance and six requirements that assess customer satisfaction of corrective maintenance services. It is concluded that the measurement of maintenance performance, by measuring customer satisfaction becomes important criterion for planning and ascertainment of industry guidelines for maintenance of the company.
Redução do tempo de setup como estratégia de aumento da capacidade produtiva: estudo de caso em sopradora de garrafas plásticas
The QFD has been used for product development for a long time. Nowadays, at the current level of maintenance, we used the QFD to innovate in the prioritization of assemblies and subassemblies that must have their planned maintenance. To achieve the proposed objectives, we firstly reviewed the literature, then analyzed the maintenance data of a production line, calculated the correlation between the needs of the sector of production with each subset of equipment that make up the line, and then constructed the QFD to prioritize the maintenance planning of the most important sets for product quality. The findings showed that the current planning model has a high level of assertiveness on the equipment schedule, but a prioritization using QFD assist in the specification of which subset undergoing maintenance, increasing the availability and reliability of equipment. The results showed there was an increase of efficiency from 79.25% to 83.76% in one year.
Este artigo apresenta um estudo de caso realizado nos setores produtivos de uma indústria de manufatura de plásticos. O problema encontrado era que a empresa controlava apenas indicadores financeiros do negócio, sendo que não haviam indicadores de desempenho para o setor produtivo. Em decorrência de desconhecer seus índices de desempenho, a empresa não avaliava a causa de problemas comuns e especiais, o que estava aumentando os custos industriais e reduzindo a margem operacional. O principal objetivo deste artigo foi desenvolver um método simples de controle de indicadores, os quais auxiliem a tomada de decisão no setor produtivo. Para alcançar esse objetivo, foi realizada uma pesquisa aplicada, de natureza quantitativa, descritiva, desenvolvida por um estudo de caso. Com o conhecimento teórico de alguns modelos de medição de desempenho e do processo, foram quantificadas as principais causas de problemas. Em seguida, foram criados indicadores de desempenho para cada setor e globais, de acordo com as necessidades da empresa. Esses indicadores de desempenho tratam os índices de materiais sucateados, de devoluções internas e externas e de tempo de máquinas paradas. Após um período inicial de coleta de dados, em fontes bibliográficas e de análise documental, se observou que os índices estão, em sua maioria, fora de controle. Isso demonstra a importância de haver controles e metas para os elementos-chave da operação de qualquer organização. Como resultados desta pesquisa, apresentam-se as telas de controle de indicadores geradas por meio de planilhas eletrônicas, onde os gestores visualizam a situação de seus indicadores em comparação com as metas propostas. Conclui-se que a elaboração deste controle tornará mais rápida a tomada de ações da empresa frente a problemas potenciais, tornando a empresa mais ágil e competitivas.
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