Implementation of Total Productive Maintenance to Enhance the Overall Equipment Effectiveness in Medium Scale Industries

Abstract

In current globe state, manufacturing companies are in need of sustaining their production level to meet the customer demand. Whenever capacity problem arises, immediately they look for increasing overtime, number of shifts and purchase new machines and equipments. As an alternative, they should focus on the better utilization of resources and increasing performance of the existing machines which leads to an improvement in the equipment performance, reduction in bottlenecks, decrease overall downtime, improve operator performance and minimize setup time and other major forms of losses, thus enabling in decision on the investment of buying new machines. In this research, an attempt was made to implement total productive maintenance to achieve overall equipment effectiveness (OEE) close to world class standards. Result analysis shows that, downtime losses are not the only influencing parameter, but idle time of a machine is anotherfactor that adds to the variation in OEE. It is evident that the percentage OEE can be improved substantially by implementing total productive maintenance lean tools such as Jishu Hozen, Kaizen etc in a manufacturing company. While calculating OEE, the factors influencing it are identified and performance improvement measures are undertaken. From the observed results, it was found that, the percentage OEE can be improved from 55.45% to 68.04% by implementing this technique in medium scale industries.

A Model to Reduce Machine Changeover Time and Improve Production Efficiency in an Automotive Manufacturing Organisation

“…The use of the presented technique results in a reduction in the cost of unit production of products, shortening the order fulfillment time, increasing the use of the working time of operators and machines, and minimizing downtime on the production line [46]. Among the additional benefits, the increase in the ergonomics of work on the line by enlarging the working space and standardizing the tools used for changeover is worth mentioning, as this was also confirmed by the authors in their research [47][48][49][50]…”

El mantenimiento productivo total como estrategia en la gestión del mantenimiento industrial

“…La implementación de TPM se centró en dos pilares, el mantenimiento autónomo mantenimiento autónomo y el mantenimiento programado solamente. Nallusamy (2018). La investigación se realiza en una industria de fabricación de tuberías de PVC a mediana escala en la India, con el objetivo de implementar un TPM para lograr una efectividad general del equipo (OEE) cercana a los estándares de clase mundial.…”

Mantenimiento productivo total en el sector manufacturero. Una revisión sistemática de literatura

“…Para determinar que problemas afectan al OEE es necesario mencionar que es una herramienta usada para la medición de la productividad [7], el cual está basado en los indicadores de disponibilidad, rendimiento y disponibilidad [4], [8]- [17]. Al hablar de problemas hay que tener en cuenta que el ser sector manufacturero, en su gran mayoría emplea el uso de maquinarias, por lo cual el OEE determina su estado actual y por donde comenzar el proceso de mejora [5].…”