Optimizing a production system using tools of total productive maintenance

Shetty, Pradeep Kumar and Shetty, Raviraj and Rodrigues, Lewlyn L R (2016) Optimizing a production system using tools of total productive maintenance. In: International Conference on Mechanical & Automobile engineering, 14/12/2016, PAATAYA-THAILAND.

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Abstract

TPM is a new maintenance strategy developed to meet the new maintenance needs and for improving productivity by making processes more reliable and less wasteful. TPM is an extension of TQM (Total Quality Management). The objective of TPM is to maintain the plant or equipment in good condition without interfering in the daily processes. To achieve this objective, preventive and predictive maintenance is required. By following the philosophy of TPM we can minimize the unexpected failure of the equipment. With regards to Total Productive Maintenance (TPM) implementation, Indian manufacturing organizations have often been plagued with teething problems and challenges. The objective of the research is to investigate the status of maintenance improvement initiatives in Indian manufacturing Industries and suggest an Indigenous TPM Methodology for the Indian industry. Basically, the methodology comprises of identifying various types of losses and failures, the actual difficulties faced during the implementation of TPM and keeping in concern the basic principles such as 100% commitment, customer driven, management and monitoring, continual improvement, frequent auditing, employee empowerment. The total productivity of machines are 0.277, 0.224 and 0.319 respectively. Thus it reflects the efficient utilization of resources (inputs) in producing goods and services (output).The Overall equipment effectiveness(OEE) for the three machines are 61.9, 61.86 and 61.85 respectively for over a period of a week. The OEE calculated is same for three machines and it gives an idea of stable production. In the Digigo India Industry in which we did our research on TPM, But in this industry OEE of more than 61% for and the productivity values were 0.224 to 0.319. In world class manufacturing systems possesses OEE of about 75 to 80%. Although the OEE can be improved a bit to make it more productive by reducing losses. Losses such as break down, maintenance, start-up defects, process defect and total defective output can be reduced and hence there can be significance increase in OEE and productivity. The plant Pradeep Kumar,Department of Mechanical & Manufacturing Engineering, ManipalInstituteofTechnology(MIT)MANIPAL576104,INDIA(phone:9449210343;e-mail:pradeep631@rediffmail.com). Raviraj Shetty, Department of Mechanical & Manufacturing Engineering, Manipal Institute of Technology(MIT) MANIPAL -576104, INDIA (e-mail: rrshetty2@rediffmail.com). Lewlyn L.R. Rodrigues, HOD, Humanities & social sciences, Manipal Institute of Technology(MIT), Manipal University, MANIPAL-576104,India. (e-mail: l.rodrigues@manipal.edu ). already follows 5s which in itself is a bigger achievement in country like India. Thus it provides a basis and enthusiasm for other organizations to follow their footsteps. This Industry had implemented all the latest industrial concepts ranging from 5S implementation to Lean Manufacturing systems. They had reduced the wastes to almost nil. With these adhering efforts of TPM and TQM, they were moreover like world class manufacturing this will also help in the reduction of wastes and will lead to the efficient working of the employees.

Item Type: Conference or Workshop Item (Paper)
Uncontrolled Keywords: KeywordsTotal Quality Management (TQM), Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE) and Productivity.
Subjects: Engineering > MIT Manipal > Mechanical and Manufacturing
Depositing User: MIT Library
Date Deposited: 31 Dec 2016 09:53
Last Modified: 31 Dec 2016 09:53
URI: http://eprints.manipal.edu/id/eprint/147840

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