STUDY OF IMPLEMENTATION OF TOTAL PRODUCTIVE MAINTENANCE … · TPM was first introduced by Seiichi Nakajima known as the Father of TPM gives basic fundamental of Total productive

STUDY OF IMPLEMENTATION OF TOTAL

PRODUCTIVE MAINTENANCE IN TEXTILE

MACHINE MANUFACTURING INDUSTRIES

Krimit Solanki1, Yadav Rakesh

2, Yadav Vishal3, Yadav Sandeep

4

Student, Mechanical department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat

Corresponding Author Detail:

Krimit Solanki

Student, Mechanical department,

Laxmi institute of Technology,

Sarigam-Valsad, Gujarat.

Internal Guide Detail:

Mr. Ankur Vashava

Assistant Professor, Mechanical department,

Laxmi institute of Technology,

Sarigam-Valsad. Gujarat.

ABSTRACT

Nowadays, consumers expect manufacturers to provide excellent quality, reliable delivery

and competitive pricing. Total Productive Maintenance (TPM) is the best tool to be

implemented in manufacturing industries to achieve good maintenance system. Nowadays

maintenance is an important factor to improve productivity and quality in manufacturing

industries.

The purpose of this paper is to implement TPM in a machine shop area in a manufacturing

industry (Yamuna m/c works ltd.) and to evaluate Overall Equipment Effectiveness (OEE) of

individual machines placed in machine shop area.

“Total Productive Maintenance is based on teamwork and provides a method for the

achievement of world class levels of overall equipment effectiveness through people and not

through technology or systems alone.” OEE (Overall Equipment Effectiveness) is used to

identify the improvement or success in TPM.

KEYWORDS: Total Productive Maintenance, Preventive Maintenance, OEE.

INTRODUCTION

In the industries huge losses/wastage occur in the manufacturing shop floor or machine shop

area. This waste is due to operators, maintenance personal, process, tooling problems and

non-availability of components in time etc. Other forms of waste includes idle machines, idle

manpower, break down machine, rejected parts etc. are all examples of waste. The main

purpose of this paper is to overcome the above losses.

In manufacturing industries the production process requires non-stop operation of automatic

production line equipment. A stoppage at any stage of the production line, due to failure of

any equipment, causes a drop in the production rate and quality of the products. Thus

productivity is the result of the changing levels of functioning of the production lines.

Total Productive Maintenance (TPM) provides a continuous, life cycle approach, to

equipment management system that minimizes equipment failures, production defects,

wastages, and accidents. It involves each and every one in an organization, from top level

management to machine operators.

International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 179

TPM was first introduced by Seiichi Nakajima known as the Father of TPM gives basic

fundamental of Total productive maintenance and aim of TPM and explains the basic steps

for implementing TPM. It establishes a thorough system of Preventive Maintenance (PM) for

the equipment’s entire life span. He also concludes that Productive Maintenance (TPM) is

positive approach to maximize equipment effectiveness.

Nippondenso was the first company to introduce Preventive Maintenance in 1960. It is the

concept where operators produced goods using machines and the maintenance group was

dedicated with the work of maintaining machines, but maintenance became a problem as

more maintenance personnel were required. So the management decided that the routine

maintenance of equipment would be carried out by operators (autonomous maintenance) and

maintenance group took up only essential maintenance works.

Thus preventive maintenance along with maintenance prevention and maintainability

improvement gave birth to productive maintenance.

CALCULATION

TPM is fully depending on calculation of Overall Equipment Effectiveness (OEE). The

main motto of increasing productivity is by calculating OEE (Overall Equipment

Effectiveness) of a particular equipment by knowing it’s efficiency. It is calculated as shown

below:-

OEE = A*PE*Q Where;

A = Availability of a machine = (Operating time/scheduled time)* 100%

PE = performance efficiency = (parts produced* ideal cycle time)/Operating time)

Q = quality rate = (total units produced-defective units)/total units produced).

We have examined 5 types of machines in machine shop area namely:

1. Milling machine.

2. Exo cutting machine.

3. Lathe machine (big hole drilling).

4. Lathe machine (boring operation).

5. Slotting machine.

MILLING MACHINE

Data collected before TPM

implementation:-

Data collected after TPM

implementation:-

Scheduled time (ST) = 12 hrs

Operating time (OT) = ST–Lunch break

time- ideal time = 12-1-2 = 9 hrs

• Availability (A)= 75%

• Quality (Q) =96%

Ideal cycle time = 2 units/hr

• Performance efficiency (PE)= 60%





• Quality (Q) = 100%

Ideal cycle time = 2 units/hr




OEE = (75*96*60)/100000 = 43.2% OEE = (75*100*60)/100000 = 45%

EXO-CUTTING MACHINE


implementation:-


implementation:-



time- ideal time- breakdown time

= 12-1-1-0.5 = 9.5 hrs



Ideal cycle time = 3 mins/unit


OEE = (79*98*60)/100000 = 46.4%



time- ideal time- breakdown time

= 12-1-1-0.5 = 9.5 hrs



Ideal cycle time = 3 mins/unit


OEE = (79*100*60)/100000 = 47.4

LATHE MACHINE (BIG HOLE DRILLING) (58mm)


implementation:-


implementation:-






Ideal cycle time = 12mins/unit


OEE = (75*99*60)/100000 = 44.5%






Ideal cycle time = 12mins/unit


OEE = (75*100*60)/100000 = 45%

LATHE MACHINE (BORING OPERATION) (108mm)


implementation:-


implementation:-






Ideal cycle time = 1hr/unit


OEE = (75*99*100)/100000 = 74.2%






Ideal cycle time = 1hr/unit


OEE = (75*100*100)/100000 = 75%



SLOTTING MACHINE (KEY)


implementation:-


implementation:-



time- ideal time = 12-1-2-.5 = 8.5 hrs



Ideal cycle time = 30min/unit


OEE = (70*99*60)/10000 = 41%



time- ideal time = 12-1-2-.5 = 8.5 hrs



Ideal cycle time = 30min/unit


OEE = (70*100*60)/10000 = 42%

HISTOGRAM CHART

Figure-1 Before implementing TPM

Figure-2 After implementing TPM



Figure-3 Fishbone diagram / Cause and effect diagram

PROBLEMS WE DEFINE IN THIS INDUSTRY

For implementing TPM the major path is of safety.

In this industry there is no proper steps against safety, some of the workers are not

provided with safety shoes.

The wires are hanging on the wall which is hazardous to the workers and operators.

The arrangement of products to be machined/operated and which are produced is not

properly scheduled.

The parts are kept anywhere.

The operators has lack of knowledge regarding production of parts they manufactured.

CONCLUSIONS

By Implementing TPM and by overcoming these above problems we came to the conclusion

that the efficiency of each machine increase which leads in increase of effectiveness of whole

machine shop area.

REFERENCES

1. Project of TPM Implementation in a Big Food Production Company – Case Study by

Diana LYJAK.

2. Internal Journal of Quality and Reliability Management Emerald Article: Total

Productive Maintenance: Literature Review and Directions by I.P.S Ahuja, J.S. Khamba.

3. Study of Total Productive Maintenance and Manufacturing Performance of a

Manufacturing Industry by Mr. Kishor Kumar Aroor.

4. Total Productive Maintenance (TPM) Concepts And Literature Review by Thomas R.

Pomorski

5. Implementing Total Productive Maintenance at an Electronic Company by Assoc. Prof.

Dr. Norzima binti Zulkifli.

6. Implementation of Total Productive Maintenance in Large Manufacturing Firms in Kenya

by Julius Induswe.

7. Analysis of Factors for Implementing TPM: A Study in Welded Tube Manufacturers by

Rodolfo Alves De Oliveira.

8. Total Productive Manufacturing (TPM) Organizing For Maximum Equipment

Productivity by Robert C.Leachman.

9. A Brief Literature Review On Total Productive Maintenance A Positive Approach To

Solve Manufacturing Problem Jignasha P Acharya.



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STUDY OF IMPLEMENTATION OF TOTAL PRODUCTIVE MAINTENANCE … · TPM was first introduced by Seiichi Nakajima known as the Father of TPM gives basic fundamental of Total productive