Approach for Total Productive Maintenance Evaluation in Water Productivity: A Case Study at Mahasawat Water Treatment Plant

Abstract

Nowadays, many water treatment plants face the problems of equipment breakdown and water loss during water production process. A method to solve these problems is to implement Eight pillars strategy (EPS), one of Total Productive Maintenance (TPM) strategy to reduce equipment breakdown, decrease water loss and enhance equipment effectiveness. Failure rate (FR), availability (A), performance efficiency (PE), quality rate (QR) were determined by evaluating equipment effectiveness through Overall Equipment Effectiveness (OEE). They were also evaluated to find the entire equipment/plant effectiveness through Net Equipment Effectiveness (NEE). In this study, the chlorinator machines in each couple phase 1&2 and 3&4 at Mahasawat Water Treatment Plant (MHS) were considered as a case study for practicing EPS. The reduction of FR and increase of A, PE and QR were revealed after practicing EPS to chlorinators as evidently evaluated in this paper. They affect to higher OEE and NEE in all couple phases. As a consequence, the chlorinators were able to operate continuously for longer time with high efficiency. The plant can also produce higher quantity of qualified water to customers by monitoring the final water treatment process via Profit Cost (PC). The proposed 17 steps for OEE, NEE and PC evaluations are shown in this paper might be a good approach for other water treatment plant to get higher chlorinator effectiveness and lower water loss.