Application of TPM in Production Process of Aluminium Stranded Conductors

Abstract

This paper presents the application of a total productive maintenance (TPM) technique to increase the effectiveness in producing aluminium stranded conductors in order to reduce waste problems of the machine and improve the quality of the production. Two pillars of TPM activities for autonomous maintenance and focused improvement are established. Machines which have low overall equipment efficiency (OEE) are selected as prototype machines. Employee training program about the production work, cleaning activities to discover abnormal conditions, corrective actions during abnormal operations and a one point lesson (OPL) to educate operators for the production process are implemented. Autonomous maintenance standards are also created. Pareto analysis is used to identify the critical equipment in the factory. A corrective action team is chosen to improve the operation of the process. The research is evaluated by comparing the OEE of prototype machines based on production problems occurred before and after the improvement. The results demonstrate that the TPM implementation decreases the downtime from 7,730.80 minutes per month to 4,942.20 minutes per month, the loss of the scrap from 4,570.00 kilograms per month to 2,236.67 kilograms per month. The OEE is increased from 67.21 percent to 72.14 percent.