Axiomatic design for lean autonomous maintenance system: an application from textile industry

Abstract

Purpose Autonomous maintenance (AM), one of the pillars of total productive maintenance (TPM), aims to achieve performance toward zero defects and zero breakdowns. AM system equipped with comprehensive lean tools provides continuous improvement during the AM activities. Despite its long duration, establishing a lean AM system with a robust guideline would provide significant benefits such as high quality and short lead time. Therefore, AM design approach should be provided in a holistic and detailed manner. This study aims to develop a framework for AM design, including preliminary, reactive, preventive and proactive steps using the axiomatic design (AD). Design/methodology/approach Requirements and technical parameters of the AM system are explored with AD. An extensive literature review and a real-life application are presented. Findings The proposed design was validated by adapting the proposed roadmap to a textile manufacturing system in Turkey. The application results justify the established AM system design with an average downtime improvement of 69.2% and the average elapsed time between two failures improvement of 65.1% for apparel department. Originality/value This study has the novelty of establishing an overall AM system design with all of its stages stepwise. It presents a comprehensive guideline in terms of integration of lean philosophy into AM design by generating maintenance-related use cases for lean tools. The developed approach facilitates creating and analyzing complex systems to improve maintenance implementations while reducing nonvalue-added operations.

Lean and industry 4.0 principles toward industry 5.0: a conceptual framework and empirical insights from fashion industry

“…For instance, some of them refer to the successful implementation of the value stream map to identify inefficiency in garment (Kumar et al, 2020), textile (Hussain and Figueiredo, 2023) and leather shoe (Reda and Dvivedi, 2022) industries. Others focus on the combination of Lean tools with autonomous maintenance to provide continuous improvement in the field, with case studies in textile companies (Kose et al, 2022) or combining them with deep learning to guide companies towards their effective implementation in real context, such as clothing companies (Elboq et al, 2023). Also, several contributions of I4.0 applications can be found.…”

Production model based on Lean Manufacturing and TPM to increase efficiency in a company in the textile sector

“…The effectiveness of the methodology is evidenced in studies where, after its application, it was possible to reduce the total production cycle time by 300 seconds, reduce the number of defective products by 5% [11], as well as increases in the OEE that vary from 11% [12] to 15% [13]. Authors choose to implement autonomous maintenance, one of the pillars of TPM, managing to reduce machine downtime by 20% and an improvement of 15% in the general efficiency of a textile company [14]. Emphasis is also placed on the importance of implementing a robust TPM framework, as productivity can be significantly improved, as well as staff training to sustain the effects of continuous improvement over time [15].…”