Umesh V. Bansode , P. M. Ambad
Abstract
The purpose of this paper is to evaluate the contribution of Total Productive Maintenance (TPM) in industry. Due to frequent failures and breakdowns occurred in machine, maintenance cost is increased and this results into different losses at workplace which cause low availability, poor performance and low quality of output of the machine. Overall equipment effectiveness (OEE) of a machine plays an important role in present scenario where delivery with quality is one of prime importance to customer. The main objective of this study is to improve OEE at a hand tools and files manufacturing company in India through the implementation of innovative techniques of TPM. Interviews with managers and operators, reviewing documentation and previous records, direct and participatory observation, these methods were used for data collection. Collected data from maintenance and production department have been evaluated and analyzed to find out bottleneck in machines. A case study is performed in Cutting cell, BS4 machines because this section is core area of the company having higher failures and rejections. A team of TPM including machine operators was formed to implement systematic TPM approach. The TPM techniques such as autonomous maintenance, planned maintenance, quality maintenance, focused maintenance and operator's training were effectively applied. As a result the company achieved overall equipment effectiveness of 80.00% from 72.28% on BS4 machine. Based on these results, maintenance manager and production manager have decided to improve their maintenance procedures and improve the productivity. Also, the company needs to work hard to improve their inspection system start from the raw materials inventory to finished goods inventory.
Keywords- Total productive maintenance, Overall equipment effectiveness, Performance efficiency, Autonomous maintenance.