Sustainability and OEE Gains in Manufacturing Operations Through TPM

Abstract

Today, the manufacturing sector necessitates a highly productive system, maintenance-free machinery and multi-skilled operator for enhanced sustainability and productivity gains. The total productive maintenance (TPM) can serve as a means of attaining these goals as well as increased productivity for industries. In this study, TPM is implemented in the manufacturing industry and overall equipment effectiveness (OEE) is calculated for machinery performance. The data is collected through a questionnaire study conducted for the employees as well as breakdown summary sheets of the industry. In the analysis, it has been observed that the forging machine takes long setup time and have a maximum number of non-value-added movements in processes. A single minute exchange of die (SMED) tool is implemented to reduce the setup time of forging machine to 67 minutes per setup, which in turn allows producing approx. 984 more products per day. A sustainable maintenance schedule is implemented for better performance of machinery and to train the workers to detect faults in the machine. A comparison of OEE before and after TPM implementation is carried out and found a significant improvement, and hence concluding that TPM helps the industry to achieve sustainability in the manufacturing industry.