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Maximize Overall Equipment Efficiency by Total Productive Maintenance

TPM aims to maximize overall equipment efficiency through total productive maintenance. It schedules maintenance as part of the manufacturing day to minimize downtime and unplanned maintenance. The goal is to identify major equipment losses through data collection and Pareto analysis. The most significant losses are addressed first by using tools like WWBLA to identify root causes and countermeasures to reduce problems and increase overall equipment efficiency.

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Labiz Saroni Zida
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83 views15 pages

Maximize Overall Equipment Efficiency by Total Productive Maintenance

TPM aims to maximize overall equipment efficiency through total productive maintenance. It schedules maintenance as part of the manufacturing day to minimize downtime and unplanned maintenance. The goal is to identify major equipment losses through data collection and Pareto analysis. The most significant losses are addressed first by using tools like WWBLA to identify root causes and countermeasures to reduce problems and increase overall equipment efficiency.

Uploaded by

Labiz Saroni Zida
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Maximize Overall Equipment Efficiency by Total Productive Maintenance

TPM brings maintenance into focus as a necessary and vitally important part of the business. Downtime for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.

Firstly, all sections of the garments factory

have been pointed out for assessment. It is observed that the goal of all factory improvement activity is to increase productivity by minimizing input and maximizing output. Equipment and machinery are the crucial factors in increasing output. Productivity, quality, cost and delivery, as well as safety, hygiene, environment, and morale are all influenced significantly by equipment conditions.

The goal of maintenance management is to

enhance equipment effectiveness and maximize output. It strives to attain and maintain optimal equipment conditions in order to event unexpected breakdowns, speed losses, and quality defects in process

Overall efficiency including economic efficiency is achieved by minimizing the cost of upkeep and maintaining optimal equipment conditions throughout the life of equipment. So the steps that were followed are: a. Identification of major losses. b. Identification of significant losses by Pareto analysis. c Calculation of Overall Equipment Efficiency (OEE). d. Reduction of losses with analytical techniques.

.The production rate of different lines in Sewing

section is considered and seen that. So, Line the lowest production rate is considered for identifying and reducing equipment losses to maximize overall equipment efficiency (OEE) by TPM pillar 3- Kobetsu Kaizen (Focused Improvement).

To identify losses and equipment efficiency, loss

data is collected for several machines for 10 days during operation Based on these data, the following major equipment losses are identified From these major losses the most significant losses are then identified by PARETO analysis

loss data for several machines


Day m/c name snls Losses Idling and minor stoppages Time (min) 6

Pareto Chart for major losses


Major losses activities Time Composition Cumulative

Idling and minor stoppages

Calculation for Overall Equipment Efficiency

the target is to increase the OEE(?%) from by

minimizing the losses.

Methodology
Here, WWBLA is used. WWBLA technique is a worksheet which

identifies the root causes of a problem. In this technique, each major problem is considered separately and a worksheet is prepared. For each major problem, a cause is identified and called it first factor for problem. Then it is verified whether it can be divided into further root causes. If it is possible, then it is marked as G. Here, G stands for Go. Then a second factor for problem is identified and verified. In this way, a third, fourth problems are identified. If it is not possible to identify further, then verification is marked as NG (Stand for No Go). Finally, countermeasures are identified for each root causes of the problem

from Pareto analysis

So, it needs to eliminate these losses first to

increase the OEE. The main cause of the most significant loss(i.e needle breakage ) WWBLA technique is used for identifying the countermeasures to reduce the problem of the problem needle breaking

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