Improvement of Overall Equipment Effectiveness (OEE) through Implementation of Total Productive Maintenance (TPM) in Manufacturing Industries

Abstract

Today competitive manufacturing requires innovative approaches in the production management, as well as for customer satisfaction. Production management requires an effective and efficient maintenance management system. One approach to improve the performance of the maintenance system is through the implementation of Total Productive Maintenance (TPM). The key performance index to measure the effectiveness of TPM implementation is Overall Equipment Effectiveness (OEE). The TPM activities will eliminate equipment losses related to availability, performance rate, and quality rate. Hence, the TPM implementation will increase the OEE value. This paper outlines the theories of TPM and OEE. The paper also presents the studies carried out by different authors to show the improvement of OEE through implementation of TPM in manufacturing, such as electronic industry, steel manufacturer, as well as locomotive components manufacturer.

Vibration monitoring of CNC machinery using MEMS sensors

“…In addition, changes and variations in the operating and environmental conditions, structural changes in the machine, variations in the use of the machine etc., usually lead to further disturbances and additional economic losses. All of these economic losses motivate special investments to improve the machine, process and operating and environmental conditions in order to reduce these losses [9].…”

Case Study in Increasing Overall Equipment Effectiveness on Progressive Press Machine Using Plan-do-check-act Cycle

“…There were many researches in automotive industry using Total Productive Maintenance (TPM) method, researching in automotive components manufacturing especially in Computer Numerical Control (CNC) machining line by improving on availability rate from 91.8 to 95.7% and it impacted to the Overall Equipment Effectiveness (OEE) value increased from 63.8% to *Corresponding Author Email: ahmadrozak66@yahoo.com (A. Rozak) 88.1% after implementing the Autonomous Maintenance [4]. Then there was research in the maintenance sector of company which supplies automotive air-conditioning tubes, the improvement could increase the availability from 75 to 85%, and there was a significant increase in OEE from 74 to 82% [5].…”

Aplicação do Controle Estatístico de Processo (CEP) para monitoramento de melhorias obtidas com o método CAPDo em uma indústria de bebidas

“…Contudo, uma falta de sinergia entre gestão da manutenção e estratégias para melhoria da qualidade, em conjunto com o não direcionamento da manutenção como estratégia competitiva vem sendo observada em algumas organizações. A implementação da metodologia Total Productive Maintenance -Manutenção Produtiva Total (MPT) fornece às organizações um guia de melhoria da eficácia das atividades de manutenção; e de transformação do chão de fábrica, integrando processos, cultura e tecnologia (KASIM et al, 2015).…”

“…O MPT é um sistema japonês único de gestão de fábrica (SWANSON, 2001), utilizado pelas empresas para a obtenção do objetivo principal do sistema, a redução à zero, ou próximo do nível zero, das seis grandes perdas dos equipamentos (KASIM et al, 2015;NAKAJIMA, 1989). Através do trabalho em equipe, atividades em pequenos grupos e a participação de todos os funcionários em iniciativas de melhoria contínua, indústrias têm alcançado esse objetivo (DAL; TUGWELL; GREATBANKS, 2000).…”