Improvement of overall equipment efficiency with root cause analysis and TPM strategy: a case study

Abedin, Ahsanul

doi:10.22105/riej.2023.393216.1388

Document Type : Research Paper

Author

Ahsanul Abedin

Khulna University of Engineering and Technology, Khulna9203.

https://doi.org/10.22105/riej.2023.393216.1388

Abstract

Nowadays, industrial businesses are more aware of the value of machine maintenance, and more especially, the adoption of an effective maintenance strategy. Total Productive Maintenance (TPM), which involves everyday chores involving the entire workforce, increases equipment efficiency, prevents breakdowns, and promotes autonomous operator maintenance. TPM is a fantastic technique for maintaining buildings and machines. This article provides research and a review of TPM implementation in an RMG Industry to help enhance Overall Equipment Effectiveness (OEE). Data from the past have been studied, and the findings obtained in terms of motivated employees, improved OEE, and a decrease in the number of rejects/accidents on the production line are fairly positive. The methodology calls for gradually applying lean principles, Autonomous Maintenance (AM), 5S, and planned maintenance. After TPM deployment on the critical machine, improvements in availability, performance, and quality are seen boosting the overall efficacy of the equipment. A comparison of OEE before and after implementation demonstrates the effectiveness of TPM deployment throughout the industry.

Keywords

Main Subjects

Total quality management and quality engineering

References

[1] Ahuja, I. P. S., & Khamba, J. S. (2008). Total productive maintenance: literature review and directions. International journal of quality & reliability management, 25(7), 709–756. DOI: 10.1108/02656710810890890

[2] Bataineh, O., Al-Hawari, T., Alshraideh, H., & Dalalah, D. (2019). A sequential TPM-based scheme for improving production effectiveness presented with a case study. Journal of quality in maintenance engineering, 25(1), 144–161. DOI: 10.1108/JQME-07-2017-0045

[3] Correia Pinto, G. F., José Gomes Da Silva, F., Octávio Garcia Fernandes, N., Carla Barros Casais, R., Baptista Da Silva, A., & Jorge Vale Carvalh, C. (2020). Implementing a maintenance strategic plan using TPM methodology. International journal of industrial engineering and management, 11(3), 192–204.

[4] Dal, B., Tugwell, P., & Greatbanks, R. (2000). Overall equipment effectiveness as a measure of operational improvement-A practical analysis. International journal of operations & production management, 20(12), 1488–1502. DOI: 10.1108/01443570010355750

[5] Ferreira, S., Silva, F. J. G., Casais, R. B., Pereira, M. T., & Ferreira, L. P. (2019). KPI development and obsolescence management in industrial maintenance. Procedia manufacturing, 38, 1427–1435.

[6] Foulloy, L., Clivillé, V., & Berrah, L. (2019). A fuzzy temporal approach to the Overall Equipment Effectiveness measurement. Computers & industrial engineering, 127, 103–115.

[7] Gapp, R., Fisher, R., & Kobayashi, K. (2008). Implementing 5S within a Japanese context: an integrated management system. Management decision, 46(4), 565–579. DOI: 10.1108/00251740810865067

[8] Guariente, P., Antoniolli, I., Ferreira, L. P., Pereira, T., & Silva, F. J. G. (2017). Implementing autonomous maintenance in an automotive components manufacturer. Procedia manufacturing, 13, 1128–1134. DOI: https://doi.org/10.1016/j.promfg.2017.09.174

[9] Herdiwan, A., & Widiyanesti, S. (2015). An analysis of machine effectiveness on the production line by using overall equipment effectiveness (OEE) method based on total productive maintenance (TPM) principle (a study case of ball tea machine in PT Kabepe Chakra). Journal of corporate governance, insurance, and risk management, 2(1), 106–118. DOI: 10.56578/jcgirm020108

[10] Hooi, L. W., & Leong, T. Y. (2017). Total productive maintenance and manufacturing performance improvement. Journal of quality in maintenance engineering, 23(1), 2–21.

[11] Lameijer, B. A., Pereira, W., & Antony, J. (2021). The implementation of Lean Six Sigma for operational excellence in digital emerging technology companies. Journal of manufacturing technology management, 32(9), 260–284. DOI: 10.1108/JMTM-09-2020-0373

[12] Lee Cooke, F. (2000). Implementing TPM in plant maintenance: some organisational barriers. International journal of quality & reliability management, 17(9), 1003–1016.

[13] Sharma, R. (2019). Overall equipment effectiveness measurement of TPM manager model machines in flexible manufacturing environment: a case study of automobile sector. International journal of productivity and quality management, 26(2), 206–222. DOI: 10.1504/IJPQM.2019.097767

[14] Gupta, P., & Vardhan, S. (2016). Optimizing OEE, productivity and production cost for improving sales volume in an automobile industry through TPM: a case study. International journal of production research, 54(10), 2976–2988. DOI: 10.1080/00207543.2016.1145817

[15] Pačaiová, H., & Ižaríková, G. (2019). Base principles and practices for implementation of total productive maintenance in automotive industry. Quality innovation prosperity, 23(1), 45–59.

[16] Mckone, K. E., & Weiss, E. N. (1998). TPM: planned and autonomous maintenance: bridging the gap between practice and research. Production and operations management, 7(4), 335–351.

[17] Gupta, P., Vardhan, S., & Haque, M. S. Al. (2015). Study of success factors of tpm implementation in indian industry towards operational excellence: an overview. 2015 international conference on industrial engineering and operations management (IEOM) (pp. 1–6). IEEE.

[18] Ng Corrales, L. D., Lambán, M. P., Hernandez Korner, M. E., & Royo, J. (2020). Overall equipment effectiveness: systematic literature review and overview of different approaches. Applied sciences, 10(18), 6469. https://doi.org/10.3390/app10186469

[19] Singh, J., Singh, H., & Sharma, V. (2018). Success of TPM concept in a manufacturing unit-a case study. International journal of productivity and performance management, 67(3), 536–549.

[20] Ur Rehman, A., Usmani, Y. S., Umer, U., & Alkahtani, M. (2020). Lean approach to enhance manufacturing productivity: a case study of saudi arabian factory. Arabian journal for science and engineering, 45(3), 2263–2280.

[21] Wang, F. K. (2006). Evaluating the efficiency of implementing total productive maintenance. Total quality management & business excellence, 17(5), 655–667. DOI: 10.1080/14783360600588232

International Journal of Research in Industrial Engineering

Improvement of overall equipment efficiency with root cause analysis and TPM strategy: a case study

References

References

Volume 12, Issue 3
September 2023
Pages 205-220

Improvement of overall equipment efficiency with root cause analysis and TPM strategy: a case study

References

References

Volume 12, Issue 3September 2023Pages 205-220

Volume 12, Issue 3
September 2023
Pages 205-220