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1
Ihueze, Chukwutoo, and Paschal Ebisike. "Optimization of Production System: An Application of Total Productive Maintenance (TPM)." Archives of Current Research International 13, no. 1 (March 15, 2018): 1–9. http://dx.doi.org/10.9734/acri/2018/38775.
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Kot, Sebastian, and Katarzyna Grondys. "Total Productive Maintenance in Enterprise Operations Support Processes." Applied Mechanics and Materials 309 (February 2013): 324–31. http://dx.doi.org/10.4028/www.scientific.net/amm.309.324.
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So far the objective of the concept of TPM has been to increase the effectiveness of production by means of involvement of operative workers at different levels in the assigned tasks. As a result, an enterprise which was focused on profits coming from its basic activity minimized production loss by implementing some preventive measures with regard to technical and technological equipment. Nowadays, the application of the concept of TPM in the area of primary processes may be insufficient to realize the assigned production targets. In the paper there are characterized the support processes which, along with the use of the principles of TPM, constitute a coherent idea while aiming at minimizing loss and not only the production loss.
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Hipkin, I. B. "A comparison of two maintenance strategies: Reliability-centred maintenance and total productive maintenance." South African Journal of Business Management 24, no. 4 (December 31, 1993): 124–29. http://dx.doi.org/10.4102/sajbm.v24i4.873.
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Improvements in the manufacturing sector have been attained through the use of a variety of management interventions. These have all concentrated on materials management and the production process. One functional area that has been neglected is the maintenance of physical assets. In this article two maintenance management approaches are compared from a philosophical and strategic point of view: reliability-centred maintenance (RCM) and total productive maintenance (TPM). The two are conceptually different, although there are common elements. Reliability-centred maintenance provides a structured methodology and concentrates on technical issues such as failure consequences and the technical feasibility and effectiveness of maintenance, with some emphasis on the human factors. Total productive maintenance seeks to maximize equipment effectiveness by the complete elimination of failures and relies on the work of autonomous groups. Much emphasis is placed on the human component From a strategic point of view, both approaches require organizational changes which may result in a dilution of managerial power.
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Astuti, Marni. "ANALISA TOTAL PRODUCTIVE MAINTENANCE MESIN CINCINNATI DI PT. DIRGANTARA INDONESIA." Conference SENATIK STT Adisutjipto Yogyakarta 2 (November 15, 2016): 25. http://dx.doi.org/10.28989/senatik.v2i0.80.
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The creation of a good product PT. DIRGANTARA INDONESIA assisted with production machines, one of which is the machine CNC MACHINE (DOUBLE CINCINNATI Milacron gantry ALUMINIUM TYPE-F), the role of a machine type-f CNC machine itself is very influential in the existing production process at PT. DIRGANTARA INDONESIA. The lack of treatment systems for the repair and replacement of components caused because the machines that is already beyond the age of many techniques, resulting in the production of the company to become unstable.In this study used methods Overall Equipment Effectiveness (OEE) and the concept of autonomous maintenance and using Failure Mode and Effect Analysis (FMEA) to determine analyze potential errors or failures, it is advisable to keep using autonomous maintenance as minor maintenance. Analysis and discussion of the results obtained OEE decline in 2014 to 2015 is 86.15% to 75.62% drop is due to the low value avalaibility, and get the highest objective value RPN 441 on a 40 point damage to component Servo Off. Solutions to make improvements to enable the Total Productive Maintenance in which includes Autonomous Maintenance. Keywords: Total Productive Maintenance (TPM), Overall Equipment Efectiveness (OEE), Autonomous Maintenance, Failure Mode and Effect Analysis (FMEA)
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Kiełbus, Anna, Dariusz Karpisz, and Tomasz Lipiński. "Process Security as the Aspect of Total Productive Maintenance." System Safety: Human - Technical Facility - Environment 2, no. 1 (March 1, 2020): 292–98. http://dx.doi.org/10.2478/czoto-2020-0036.
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AbstractThe paper presents the importance of process security as one of the parts of Total Production Maintenance. Knowledge about the standards and factors used in monitoring production processes has been systematized. The good manufacturing practices in production continuity management are presented in the article.
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Singh, Samandar, Prof D. S. Kumani Prof. D. S. Kumani, and Ved Parkash. "Total Productive Maintenance." International Journal of Scientific Research 2, no. 3 (June 1, 2012): 152–53. http://dx.doi.org/10.15373/22778179/mar2013/48.
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Haming, Puadi, Mahfud Nurnajamuddin, Hamzah Hafied, and Serlin Serang. "Effect of Work Attitude and Total Productive Maintenance on the Overall Equipment Effectiveness and Production Continuity." IRA-International Journal of Management & Social Sciences (ISSN 2455-2267) 7, no. 3 (June 23, 2017): 423. http://dx.doi.org/10.21013/jmss.v7.n3.p3.
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<div><p><em>This study aims to examine and analyze the impact of work attitude, Total Productive Maintenance (TPM) on the Overall Equipment Effectiveness (OEE) and production continuity and the other effect of Work Attitude and Total Productive Maintenance (TPM) on production continuity: The mediating role of Overall Equipment Effectiveness (OEE). The research was conducted at PT. Semen Tonasa i.e. units II to V unit which is the largest cement producer in eastern Indonesia. Withdrawal of respondents did with the criteria that only respondents yang having their respective sectors and who have work experience of at least one year were used as samples. Results of analysis Partial Least Square (PLS) Version 2.0.M3 used in analyzing the contribution of exogenous variables on endogenous variables directly, Sobel Test was used for pushing analyze the contribution of the indirect effect (mediation) whereas importance- performance analysis (IPA) to analogous interpret the relationship loading factor value and the average value. The results of this study provide evidence of work attitude has a positive and significant effect on the overall equipment effectiveness (OEE), total productive maintenance (TPM) has a positive and significant effect on overall equipment effectiveness (OEE), work attitude, total productive maintenance (TPM) and overall equipment effectiveness (OEE) positive and significant impact on production continuity.</em></p></div>
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Balouei Jamkhaneh, Hadi, Javad Khazaei Pool, Seyed Mohammad Sadegh Khaksar, S. Mohammad Arabzad, and Reza Verij Kazemi. "Impacts of computerized maintenance management system and relevant supportive organizational factors on total productive maintenance." Benchmarking: An International Journal 25, no. 7 (October 1, 2018): 2230–47. http://dx.doi.org/10.1108/bij-05-2016-0072.
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Purpose The application of automated systems is rapidly increasing in different industries and organizations. In this regard, computerized maintenance management systems (CMMS) using information technology play an important role in the automating production systems. The purpose of this paper is to investigate the impacts of CMMSs and relevant supportive organizational factors on the effectiveness of total productive maintenance. Design/methodology/approach This study is classified as a quantitative survey-based research using structural equation modeling. The scope of the study includes manufacturing companies in Iran. A total of 125 questionnaires from 60 companies were collected from January to March 2014 to help validate the conceptual model and test the hypotheses. Findings The results support the concept CMMSs positively relates to relevant supportive organizational factors (resource allocation, decision-making structure, senior management support, employees’ involvement and effective instruction) on the effectiveness of total productive maintenance. The relevant supportive organizational factors can also be seen as the predictors of CMMSs. Originality/value This study integrates the CMMSs and relevant supportive organizational factors in a robust model to examine the effectiveness of total productive maintenance. This study also examines the impacts of CMMSs and relevant supportive organizational factors on total productive maintenance which seems to not be done previously.
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Pascu, Cristina Ileana, Ilie Dumitru, Stefan Gheorghe, and Mihai Nisipasu. "Implementation of Total Productive Maintenance Principles for Quality Improvement in an Automotive Company." Applied Mechanics and Materials 880 (March 2018): 171–76. http://dx.doi.org/10.4028/www.scientific.net/amm.880.171.
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In the automotive field, the application of Lean Manufacturing principles has become a common practice in recent decades. One of the basic methodologies of Lean philosophy is the Total Productive Maintenance (TPM). The TPM includes a number of methods initially designed to ensure the continuous operation of the machines involved in the production process so that production is never interrupted. In this paper some of the most important steps in quality improvement by implementation of TPM in an automotive company are presented. It is described the monthly implementation extent of TPM indicators starting from 2014 until now, especially on the production lines of the factory. Finally, the major benefits of TPM principles implementation in the company are highlighted.
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Duques Maciel Filho, Aglei, Jonas Gomes da Silva, and Mariana Sarmanho de Oliveira Lima. "Impact of Autonomous Maintenance on a PIM Production Line." International Journal for Innovation Education and Research 7, no. 12 (December 31, 2019): 385–98. http://dx.doi.org/10.31686/ijier.vol7.iss12.2084.
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To increase the competitiveness of their products, companies have sought to identify and eliminate losses in their production processes to reduce production costs. One of the six major process losses established by the Total Productive Maintenance (TPM) philosophy is related to equipment downtime in the production environment. This paper analyzes the impacts of the implementation of autonomous maintenance through the eight-step analysis implemented by a project developed in line 3 of the welding sector of a factory located in the city of Manaus, capital of Amazonas, Brazil. To this end, the indicators were evaluated, establishing the solution priority, defining the necessary actions and implementing them. Upon completion of the project, there was a 39% increase in operators' knowledge of machines and autonomous maintenance procedures, as well as a 75% reduction in line equipment downtime, increasing the availability from 94.9% to 98.7%, allowing to verify the effects of the execution of the autonomous maintenance activities.
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Reyes, John, Kevin Alvarez, Amanda Martínez, and Juan Guamán. "Total productive maintenance for the sewing process in footwear." Journal of Industrial Engineering and Management 11, no. 4 (November 30, 2018): 814. http://dx.doi.org/10.3926/jiem.2644.
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Purpose: This research proposes an implementation model of Total Productive Maintenance (TPM) based on the analysis of criticality of machines in the sewing process in the Ecuadorian footwear industry and the identification of unproductive times caused by labor failures.Design/methodology/approach: The project uses field research, presents a quantitative approach, the data collection is done in a horizon of 8 months in which the information is condensed in data tables and takes as a case study one of the most successful companies in the Ecuadorian footwear industry for its initiative to innovate their processes and research new technologies that help increase their efficiency.Findings: The results allow to demonstrate the successful application of the proposed model in the industrial sector of footwear with an increase of average production standards of 5% and a reduction in the number of human errors of 72.2%.Practical implications: The model allows to execute several activities in four phases: preparatory, introduction, implementation and consolidation in order to develop TPM in sewing process.Originality/value: The paper describes a case study in a major shoe company with the aim of reducing the times for unscheduled stoppages and the number of failures.
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Kasim, Nazrul Idzham, Mohd Azam Musa, Akhtar Razul Razali, Noraishah Mohamad Noor, and Wan Ahmad Najmuddin Wan Saidin. "Improvement of Overall Equipment Effectiveness (OEE) through Implementation of Total Productive Maintenance (TPM) in Manufacturing Industries." Applied Mechanics and Materials 761 (May 2015): 180–85. http://dx.doi.org/10.4028/www.scientific.net/amm.761.180.
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Today competitive manufacturing requires innovative approaches in the production management, as well as for customer satisfaction. Production management requires an effective and efficient maintenance management system. One approach to improve the performance of the maintenance system is through the implementation of Total Productive Maintenance (TPM). The key performance index to measure the effectiveness of TPM implementation is Overall Equipment Effectiveness (OEE). The TPM activities will eliminate equipment losses related to availability, performance rate, and quality rate. Hence, the TPM implementation will increase the OEE value. This paper outlines the theories of TPM and OEE. The paper also presents the studies carried out by different authors to show the improvement of OEE through implementation of TPM in manufacturing, such as electronic industry, steel manufacturer, as well as locomotive components manufacturer.
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Rizlan, Wardah, Humiras Hardi Purba, and Sudiyono Sudiyono. "Performance Maintenance Analysis Using QFD Method: A Case Study in Fabrication Company in Indonesia." ComTech: Computer, Mathematics and Engineering Applications 9, no. 1 (June 30, 2018): 25. http://dx.doi.org/10.21512/comtech.v9i1.4456.
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This research aimed to determine the needs and wants of production and management team to improve the machine and performance maintenance. Voice of the Customer (VOC) method was used to capture the needs and wants of production and management team. Meanwhile, the method of Quality Function Deployment (QFD) was used to translate the needs and wants of production and management to the technical requirement that should be done to improve machine and performance maintenance. Moreover, Total Productive Maintenance (TPM) was a part of technical requirement. From the result, it is known that long breakdown machine, huge inventory of spare part, and high cost of maintenance become the first of priority of maintenance team to achieve customer satisfaction. To develop the performance maintenance, the company should standardize the procedure, identify the critical spare part, reduce the time to purchase critical spare part, and increase lifetime of spare part.
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Chang, Peng, and Yin Hui Ao. "Maintenance Optimization of the OLED Manufacturing Process." Applied Mechanics and Materials 577 (July 2014): 90–93. http://dx.doi.org/10.4028/www.scientific.net/amm.577.90.
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OLED (Organic light-emitting diodes) is a kind of brand-new display technology. The production involves many processes and different equipments. We studied the optimization problem of interval of preventive maintenance in OLED processes. With the help of ExtendSim software, we perform quantitative analysis and adjusted the productive process. Considering the cost of the preventive maintenance and random corrective repair, We optimized the interval of periodic maintenance with the limit of total output and obtained the best profit and lowest maintenance cost.
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Fam, Soo-Fen, Ser Lee Loh, M. Haslinda, Heri Yanto, Linda Mei Sui Khoo, and Diana Hwa Yieng Yong. "Overall Equipment Efficiency (OEE) Enhancement in Manufacture of Electronic Components & Boards Industry through Total Productive Maintenance Practices." MATEC Web of Conferences 150 (2018): 05037. http://dx.doi.org/10.1051/matecconf/201815005037.
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In an environment of intense global competition, both creative and proven strategies need to be considered in order to bring about the effectiveness and efficiency in manufacturing operation. Total Productive Maintenance (TPM) is one of the effective maintenance strategy in enhancing the equipment effectiveness and to achieve a significant competitive advantage. This research paper addresses the impact of three TPM pillars namely planned maintenance (PM), autonomous maintenance (AM) and focused maintenance (FM) on overall equipment effectiveness (OEE) of die attach equipment in the production line of semiconductor industry. The effect of TPM on the OEE is also investigated depending on the equipment types, in where die attach process consist of two models-CANON and ESEC. The primary data was collected from an organization's database and was analysed by SPSS V23. The preliminary results of the analysis showed that the performance of OEE in ESEC is better than the CANON after the implementation of TPM. The analysis also showed that out of the three TPM practices deployed, planned maintenance of equipment by production and maintenance team played the biggest role in increasing the equipment effectiveness. In conclusion, this study provides insights the importance of implementing TPM in order to succeed in a highly demanding market arena.
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Okhovat, Mohammad Amin, Taravatsadat Nehzati, Amin Pouriran, Shahriar Fakhar, and Mohd Khairol Anuar Mohd Ariffin. "Improving Equipment Effectiveness by Designing Optimal Production Process." Advanced Materials Research 383-390 (November 2011): 6363–69. http://dx.doi.org/10.4028/www.scientific.net/amr.383-390.6363.
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Reliable manufacturing equipment is an indispensable factor to the performance and profitability of manufacturing systems. Total productive maintenance (TPM) has been recognized as a comprehensive manufacturing strategy to maximize equipment reliability and effectiveness through rooting out all manufacturing losses. Availability of equipment is a focus area in TPM to improve effectiveness throughout the lifetime of the equipment. This study develops a mixed integer linear programming model to increase equipment availability considering maintenance cost of each machine in the system. The main objective is minimizing total cost while designing optimal material flows between different operational levels of manufacturing process. A hypothetical problem is presented and solved by the developed model.
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Sahoo, Saumyaranjan, and Sudhir Yadav. "Lean production practices and bundles: a comparative analysis." International Journal of Lean Six Sigma 9, no. 3 (August 6, 2018): 374–98. http://dx.doi.org/10.1108/ijlss-01-2017-0002.
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PurposeTotal productive maintenance and total quality management are two lean manufacturing initiatives that are used by manufacturing plant managers to improve operations capabilities. The purpose of this paper is to investigate the effects of standalone lean practices and lean bundles on manufacturing business performance.Design/methodology/approachA quantitative approach was used. The survey data were drawn from 160 manufacturing organizations in India. The respondent companies were grouped on the basis of the duration of lean production in operation and then classified based on the profile of their operations strategy. The approach, based on comparative assessment between standalone lean practices and lean bundles, has been directed toward justification of lean bundles for its support to competitive manufacturing in the context of the Indian manufacturing sector.FindingsThe paper establishes the long-term effects of lean bundles in significantly improving manufacturing business performance as compared to standalone lean practices. Further findings of the study revealed the significance of the duration of lean production in operation in achieving higher levels of manufacturing business performance.Research limitations/implicationsThe study is cross-sectional in nature. It would be interesting to test the analytical framework adopted for this study for more industries and in different countries. The use of subjective measures in survey questionnaire is also another limitation of the study.Practical implicationsThis study offers clear implications for practitioners, proving that they should give higher emphasis on the implementation of lean bundles using total productive maintenance and total quality management practices together, to prioritize their product, production and business strategies, to achieve sustainable competitive advantage.Originality/valueThis paper empirically examines and evaluates the effect of lean practices and bundles in the context of medium- and large-sized manufacturing industries in India. Besides, there are very few studies that comparatively assess the differences in performance contribution of various lean operational strategies considering duration of implementation of lean. Also, the theoretical contribution of the study establishes the essence of integrating total productive management and total quality management for attaining world class manufacturing is of high value.
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Hardt, Filip, Martin Kotyrba, Eva Volna, and Robert Jarusek. "Innovative Approach to Preventive Maintenance of Production Equipment Based on a Modified TPM Methodology for Industry 4.0." Applied Sciences 11, no. 15 (July 28, 2021): 6953. http://dx.doi.org/10.3390/app11156953.
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Preventive maintenance (PM) in the production industry is one of the most essential measures to eliminate accidental machinery failures by replacing/repairing worn out machines or parts. The decision of when and where to perform preventive maintenance is non-trivial due to the complex and stochastic nature of the industry where PM is implemented. This article deals with the theoretical and practical implementation of preventive maintenance based on a unique modification of the total productive maintenance (TPM) methodology. The innovative approach of preventive maintenance management was implemented in the real production hall of ITT (Czech Republic) and has been verified. Within preventive maintenance, the new concept brings in an innovative method of managing the maintenance process as a whole, from abstract methodical conception to practical usage. The whole new approach has been verified and implemented on industrial equipment. A challenging task while implementing Industry 4.0 technologies is the issue of how to fully gather and analyse operational data from various items of equipment and users under various conditions, which would result in innovative services of equipment maintenance for clients. The solution to this problem is based on an innovative approach to preventive maintenance of complex equipment and could help many industrial companies to increase production and maintenance efficiency.
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Farsijani, Hassan, Mohsen Shafiei Nikabadi, and Fatemeh Mojibian. "The Role of Total Productive Maintenance in Group Technology to Achieve World-Class Status." International Journal of Applied Industrial Engineering 1, no. 2 (July 2012): 25–35. http://dx.doi.org/10.4018/ijaie.2012070103.
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The purpose of this paper is to illustrate how the World Class Manufacturing (WCM) techniques influence in implementation of Total Productive Maintenance (TPM) in cellular manufacturing. The paper presents an investigation of TPM which can be defined in terms of Overall Equipment Effectiveness (OEE). Then, using a case study in Cement Industry, OEE index that is related with TPM implementation in a cell with performance standards of world class Manufacturing is compared. Implementation of TPM in cellular manufacturing brings competitive advantages such as increasing efficiency and improving maintenance quality in cellular manufacturing systems. The first step to World-Class Manufacturing is to implement TPM successfully and to create a very active organization. When TPM has been a common practice in daily production, it can be said that company has just commenced a journey to world-class manufacturing. So, the originality of this paper is to assessing The Role of Total Productive Maintenance in Group Technology to achieve world-class status.
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Hj. Bakri, Adnan, Abdul Rahman Abdul Rahim, and Noordin bin Mohd Yusof. "Maintenance Management: Rationale of TPM as the Research Focus." Applied Mechanics and Materials 670-671 (October 2014): 1575–82. http://dx.doi.org/10.4028/www.scientific.net/amm.670-671.1575.
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This paper aims to examine the Total Productive Maintenance (TPM) as the significant technique to improve the maintenance management of production equipment. Attempt was made to discuss the available literature related to existing techniques in maintenance management, particularly on breakdown maintenance (BM), preventive maintenance (PM), predictive maintenance (PdM) or condition-based maintenance (CBM), reliability-centered maintenance (RCM), computerized maintenance management system (CMMS) and TPM. The outcomes from these reviews would serve as useful guidelines for the future research in maintenance management. This review justifies TPM as a comprehensive technique to improve the flaw in maintenance management. Notably, TPM encompasses of all elements applied by other maintenance methodology, from tools and techniques to involvement of all operational hierarchical in the organization as what is very much required in manufacturing organization is to integrate different functional areas in a coherent manner.
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K, S. R. Chandra Shashidhar, and Dr Devendra S. Verma. "Human Aspects in Implementation of Total Productive Maintenance." International Journal of Trend in Scientific Research and Development Volume-2, Issue-2 (February 28, 2018): 326–33. http://dx.doi.org/10.31142/ijtsrd9396.
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Cahyono, Sigit Dwi, Fourry Handoko, and Nelly Budiharti. "Calculation of Overall Equipment Effectiveness (OEE) in Rotary Machine 5 Feet in Order to Total Productive Maintenance Implementation." International Journal of Innovative Science and Research Technology 5, no. 7 (August 11, 2020): 1199–204. http://dx.doi.org/10.38124/ijisrt20jul625.
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PT. Tri Tunggal Laksana is an industry that focusing on wood processing. During the production period, the tools have a high frequency of trouble. Total Productive Maintenance (TPM) has been recognized as one of the significant operation strategy to regain the production losses due to equipment inefficiency. Many organizations have implemented TPM to improve their equipment efficiency and to obtain the competitive advantage in the global market in terms of cost and quality. In the implementation of TPM in a manufacturing organization, both Human-oriented and Process-oriented strategy has been identified as critical success factors. Based on the problem background, the research do because Rotary Machine 5 Feet having so many trouble in July to December of 2019 during the production period. After the research is done, the average of OEE calculation is equal to 56.29%. It can be concluded that the effectiveness of the machine is still far from world class standard that is equal to 85%. Six big losses factors that contribute most to Rotary Machine effectiveness is Reduce Speed Losses that is 22,31%. According to the fishbone diagram analysis factors that causing the OEE is low can be identified so that improvement can be done immediately.
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Bartz, Teonas, Julio Cezar Mairesse Siluk, and Ana Paula Barth Bartz. "Improvement of industrial performance with TPM implementation." Journal of Quality in Maintenance Engineering 20, no. 1 (March 4, 2014): 2–19. http://dx.doi.org/10.1108/jqme-07-2012-0025.
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Purpose – The purpose of this paper is to show the implementation of a maintenance management model based on total productive maintenance (TPM) in a production line of a metallurgical company, with high-precision equipment requiring effective maintenance to maintain the quality of the production process. Design/methodology/approach – Has been proposed a model for conducting the activities, emphasizing the training activities of the teams involved in the implementation, collection and analysis of industrial performance indicators from a year before the implementation of TPM. The development followed the timetable of activities and the results of these performance indicators were collected again after the application of the model. Findings – It observed that after the implementation of TPM, and the results of these performance indicators were collected again after the application of the model. Thus, it is concluded that the TPM assists in improving industrial performance and competitiveness of the production line studied. Originality/value – The angle, from which the paper approaches the TPM problem, is original for the studied company and shows positives results. It allows the company to apply the model in their others production lines and factories to achieve an improvement in industrial performance and competitiveness.
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Lin, Xiang Jie, Qiang Lin, and Guang Na Zhang. "Effectivity of Total Productive Maintenance (TPM) in Large Size Organizations – A Case Study in Shandong Lingong." Applied Mechanics and Materials 701-702 (December 2014): 1249–52. http://dx.doi.org/10.4028/www.scientific.net/amm.701-702.1249.
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Poor information of TPM case study can be found, which is important for TPM implementation. This paper introduced TPM implementation in Shandong Lingong (SDLG) with two years of data collection and practice. The company conducted equipment classification, production plan improvement, failure rate reduction, spare parts management and staff training practices based on MTTR, MTBF and OEE figures. Results showed that MTTR is complicate while MTBF and OEE showed better fits with the company reality of TPM. Thorough the practice and execution of TPM the company get better OEE and less breakdown time, which increase the production efficiency in the end.
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Tian Xiang, Zhang, and Chin Jeng Feng. "Implementing total productive maintenance in a manufacturing small or medium-sized enterprise." Journal of Industrial Engineering and Management 14, no. 2 (February 5, 2021): 152. http://dx.doi.org/10.3926/jiem.3286.
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Purpose: This paper develops a ‘light’ total productive maintenance (TPM) model suitable for small and medium-sized enterprises (SMEs). By design, the system is rudimentary, using a relatively small sum of capital investment and resources. The model recommends TPM implementation in three stages, namely plan, improve, and sustain.Design/methodology/approach: The literature review provides the inputs to the model development. Action research is used to demonstrate and verify the effectiveness and practicability of the framework, in an SME manufacturing hydraulic parts in China. Overall Equipment Effectiveness (OEE) and awareness of employees were studied before and after the implementation. Findings: The case study shows a significantly improved production efficiency of the equipment. The framework structuralizes TPM deployment and binding different levels of the organization into the program, from planning, implementation to sustaining the practices. To break the barrier of shop-floor resistance, the leader must drive many activities unassisted, it, therefore, necessitates an open endorsement of authority by the steering committee composed of top management. The Prudent pilot run of TPM helped to accelerate the implementation at critical equipment, in addition to cultivating experience and hence confidence among staff.Research limitations/implications: This study provides a pragmatic reference to other researchers and practitioners to promote a light TPM model in SMEs, without losing the essence of TPM. Being action research with the case study in a specific manufacturing industry, the resultant evidence, therefore, is anecdotal.Originality/value: The model adopts a phased method to implement TPM, without aggravating the financial and human resource burden of the enterprise. It promotes the cultivation of employees’ TPM awareness and active involvement, which can lay a solid foundation for the wide implementation of TPM in SMEs.
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Martin, Hector, Fey Mohammed, Kevin Lal, and Shannon Ramoutar. "Maintenance strategy selection for optimum efficiency – application of AHP constant sum." Facilities 38, no. 5/6 (December 16, 2019): 421–44. http://dx.doi.org/10.1108/f-05-2018-0060.
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Purpose There are limited studies addressing how choosing a maintenance strategy can contribute towards maximising outputs from given inputs, thereby minimising costs and improving a company’s competitiveness. The analytic hierarchy constant sum method (AHCSM) is used to access the appropriateness of maintenance strategies for improving the overall efficiency of a structural steel fabrication construction company. Design/methodology/approach A semi-structured interview was formulated with the stakeholders of the quality department to understand the company’s maintenance portfolio and its current functional capability. The information from this case study was then dissected to represent the factors that the company deemed appropriate for evaluating their maintenance strategy. The AHCSM approach provided a framework, which ranked the importance of factors that are sensitive to the construction industry and rank the suitability of maintenance strategies. Findings Factors affecting the selection of maintenance strategies to improve business efficiency are productivity, quality, reliability, cost, safety and work environment, morale, inventory and flexibility. Total productive maintenance strategy produces the most desirable outcome; however, the predictive or condition-based maintenance strategy provides an optimum solution for the case study company while considering the equipment usage, frequency of production and the current economic climate. Originality/value The approach presented allows practitioners to consider ways to increase the level of production and improve the efficiency of construction businesses without a high increase in investment. The findings can inform gaps in existing maintenance approaches in achieving business objectives.
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Tsarouhas, Panagiotis. "Improving operation of the croissant production line through overall equipment effectiveness (OEE)." International Journal of Productivity and Performance Management 68, no. 1 (January 14, 2019): 88–108. http://dx.doi.org/10.1108/ijppm-02-2018-0060.
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Purpose Overall equipment effectiveness (OEE) is a metric for estimating equipment effectiveness of the industrial systems. The purpose of this paper is to identify maintenance improvement potentials using an OEE assessment within the croissant production line. Design/methodology/approach The present work is carried out by analyzing the failure and repair data of the line. The failure data cover a period of 15 months. During this period the croissant production line usually operates over the entire day (24 h per day) in three 8-h shifts per day, and pauses at the weekends. Descriptive statistics of the failure and repair data for the line based on scheduled and unscheduled interruptions were carried. Moreover, the actual availability (A), performance efficiency (PE) and quality rate (Q) measures, together with the complete OEE for each working day for the croissant production line, were shown. Findings The main objectives are to understand the operation management of the croissant production line, and to measure the OEE characteristics in precise quantitative terms. OEE analysis can help the company to identify the primary problems concerning the A, PE and Q and acts immediately. Originality/value This paper presents a successful evaluation of OEE which will provide a useful guide to aspects of the production process, which identifies the critical points of the line that require further improvement through effective maintenance strategy (i.e. total productive maintenance). Moreover, the analysis provides a useful perspective and helps managers and engineers make better decisions on how to improve manufacturing productivity and quality.
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Seligman, N. G., M. Gutman, Z. Holzer, I. Noy Meir, and H. Baram. "Stocking density of cattle and herbage production on Mediterranean grassland." Journal of Agricultural Science 113, no. 1 (August 1989): 51–58. http://dx.doi.org/10.1017/s0021859600084604.
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SUMMARYA Mediterranean grassland was grazed with beef cattle at 0·5, 0·67 and 0·83 cows/ha, all the year round for 5 years. Range forage became increasingly scarce during the dry season, especially at high stocking density, and more supplementation was needed to maintain the animals. Herbage consumption was calculated from standard requirements for recorded body weight and performance. Maintenance requirements were multiplied by a grazing activity factor of 1·6.Mean annual herbage dry matter production was estimated at c. 3·06 ± 0·137 t/ha. Most of the variation between years was due to a particularly productive year in 1978. Contrary to expectation, stocking density had a small effect on total herbage production, despite significant differences in animal performance. It appears that herbage production of the seasonally temperate herbaceous range, typical of the basaltic hills in eastern Galilee in Israel, is not limited by total annual rainfall. Alternative limiting factors are nutrient deficiency and restricted rooting zone, or a combination of both.
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Djekic, Ilija, Dragan Zivanovic, Sladjana Dragojlovic, and Radoslava Dragovic. "Lean Manufacturing Effects in a Serbian Confectionery Company – Case Study." Organizacija 47, no. 3 (August 22, 2014): 143–52. http://dx.doi.org/10.2478/orga-2014-0013.
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AbstractBackground and Purpose: The objective of this paper was to evaluate effects of implementing lean manufacturing in a Serbian confectionery production company during a period of 24 months, emphasizing observed benefits and constrains. Company ‘case study’ is a leading confectionery producer in Serbia with annual production of more than 25,000 t.Methodology/Approach: The research method was case study. The approach in implementing lean manufacturing was structured in five phases, as follows: (i) training, (ii) analysis of lean wastes on one technological line, (iii) choice of lean tools to be implemented in the factory, (iv) implementation of lean tools in production and maintenance, (v) development of continual improvement sector and further deployment of lean tools.Results: Lean manufacturing tools implemented in the production process were visual control and single minute exchange of dies (SMED). Maintenance process implemented 5S with total productive maintenance (TPM) and problem solving sessions being the tools implemented in both processes. During the observed period, results of these tools showed the following: visual control tables initiated 61 improvement memos out of which 39% were fully implemented; a total of 2284 minor problems had been recorded, with over 95% of issues revealed in due time; total SMED time decreased for 7.6%; 19 problem solving sessions were initiated with 58% of solving effectiveness, and the remaining converted to on-going projects. In maintenance 5S improved from 29.9 to 60.3; overall equipment effectiveness (OEE) indicator increased from 87.9% to 92.3%; mean time between failure (MTBF) increased for 16.4%. Conclusion: As a result of all activities, 20 in-house trainings and 2 ‘kaizen’ events including motivational training have been initiated with 54 documents being revised and improved in order to contribute to more efficient processes.
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Graisa, Mustafa, and Amin Al‐Habaibeh. "An investigation into current production challenges facing the Libyan cement industry and the need for innovative total productive maintenance (TPM) strategy." Journal of Manufacturing Technology Management 22, no. 4 (May 3, 2011): 541–58. http://dx.doi.org/10.1108/17410381111126445.
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Hladiy, M. V., O. V. Kruglyak, and I. S. Martynyuk. "CRITERIA FOR ECONOMIC EVALUATION UNPRODUCTIVE COSTS FOR DAIRY CATTLE MAINTENANCE." Animal Breeding and Genetics 54 (November 29, 2017): 14–19. http://dx.doi.org/10.31073/abg.54.02.
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Costs are an important economic category that have a decisive influence on the definition of pricing policies and the formation of financial performance of the enterprise, characterizing the level of organization of production and application of technologies. According to expediency of their spending, costs are divided into productive and unproductive. Unproductive costs arise in the event of a violation of technology, deficiencies in the organization of production, etc. Therefore, it is necessary to ensure that the economic evaluation of unproductive costs in breeding dairy cattle is carried out in order to determine their volume and specific weight in total expenses.
An economic evaluation unproductive costs for dairy cattle maintenance should be carried out on the basis of criteria that take into account the main factors affecting the efficiency. These criteria include innovation, production, market, social and environmental. Their assessment under all criteria is conducted using the methods of economic analysis. The reasons and dynamics of their emergence should be the subject of a thorough study of management accounting and financial management of enterprises.
According to the analysis of the structure of the cost of livestock production in state enterprises "Experimental farm "Niva" and "Experimental farm "Khrystynivske" that are part of the network of the Institute of Animal Breeding and Genetics nd. a. M.V.Zubets NAAS (Cherkasy region) (Table 1 ), in the structure of the cost of milk production the largest share is the cost of feed (42.6%) and labor remuneration combined with accrual (20.4%). In the production of live weight of cattle for feed and wages account for 76.6% of all costs.
Rational use of feed is one of the main ways to strengthen the economy of the enterprise. In order to avoid unproductive costs, it is necessary to observe all technological stages of production, storage, distribution and feeding of forages. Provision for increasing the efficiency of feed costs is to increase the conversion of feed to products and reduce the cost of the diet and its individual components. In particular, finding suppliers with lower prices for concentrated feeds and milk replacers, growing fodder crops with higher nutrition.
The system for keeping animals is also important. For example, with untied, labor costs by 67% lower than with tied, the profitability of milk production is increased by 4%.
The most economic losses to farms are caused by diseases of the mammary gland, which lead to a decrease in the milk productivity of cows, the quality of milk; an increase in the incidence of calves, and the abandonment of livestock. At present, the total unproductive costs of udder disease are estimated at the equivalent of 5-8% of the gross annual income, or from 2.6 to 4.1 thousand UAH. per cow.
Other unproductive costs of dairy cattle maintenance of productivity direction are financial losses from the reduction of genetic potential, prolongation of the interotional period, the reduction of duration of the economic use of cows, the low quality of milk and the non-equivalent milk sales prices.
Comprehensive economic assessment of unproductive costs, determined in accordance with innovative production, market, social and environmental criteria, will allow, in conditions of relative limited resources, to ensure the effective management of production processes of breeding dairy cattle, aimed at increasing profits.
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Rezig, Ahmida, Ahmed Yousfi, Sylvain Fréour, Frédéric Jacquemin, and Samuel Branchu. "Nouvelle méthode de maintenance CBM pour améliorer la durée de vie des pales d’éoliennes implantées dans les zones arides." MATEC Web of Conferences 261 (2019): 01001. http://dx.doi.org/10.1051/matecconf/201926101001.
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l’amélioration de la durée de vie des pales éoliennes opérant dans une région aride au-delà de sa durée de vie habituelle de 20 ou 25 ans oblige leur propriétaire à augmenter le nombre des inspections dans le cadre de la maintenance préventive sachant que les coûts de maintenance et d’arrêt d’une d’éolienne ont un impact direct sur la production totale et peuvent représenter jusqu’à 25% de l’énergie produite. Sachant que dans une région poussiéreuse, les pales sont soumises à une usure érosive qui contribue à la modification de la forme aérodynamique du bord d’attaque et réduit ainsi les performances de l’éolienne. Ce papier décrive et propose une nouvelle méthode de maintenance CBM pour améliorer la durée de vie d’une pale éolienne. Les résultats expérimentaux montrent que l’utilisation de cette méthode est très efficace pour détecter toute dégradation provoquée par l’usure érosive à la surface d’une pale pendant son service.
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Malatji, Thabiso, and Goodwell Muyengwa. "Productivity Improvement in a Vegetable Canning Manufacturing Facility." MATEC Web of Conferences 312 (2020): 05004. http://dx.doi.org/10.1051/matecconf/202031205004.
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This paper investigates current productivity levels of baked beans in a fast manufacturing consumer goods (FMCG) company. The market demand for baked beans on average has increased by 14% year on year over the past two to three years. This growth was unexpected and was unplanned for, hence equipment was utilized to maximum capacity, at times ignoring maintenance issues. The outcome of this approach was a major concern of unplanned stoppages on the production line. The canning process has manual activities such as soaking and sorting. Blanching is semi¬automatic while filling and seaming are fully automated. The filling station was identified as the bottleneck station due to its slow speed (145 cans/minute) as compared to the seamer (200 cans/minute). The major objective of this study was to evaluate how the productivity of the canning process was achieved. Efforts were made to increase the output of soaking, sorting and blanching. This led to the reduced cycle time of the filler and the elimination of sources of contaminations. Industrial engineering tools such as autonomous maintenance, total productive maintenance, total quality management and some of the 20 keys were used to improve the plant’s production output. This paper contributes to the theory of productivity improvement and to industry practitioners it highlights challenges faced when improving productivity.
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Szulc, Tomasz. "Analysis of possibilities of implementation of Total Productive Maintenance (TPM) concept in public services organisations." Mechanik, no. 7 (July 2015): 568/821–568/830. http://dx.doi.org/10.17814/mechanik.2015.7.302.
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Prabowo, Herry Agung, Yudha Bobby Suprapto, and Farida Farida. "THE EVALUATION OF EIGHT PILLARS TOTAL PRODUCTIVE MAINTENANCE (TPM) IMPLEMENTATION AND THEIR IMPACT ON OVERALL EQUIPMENT EFFECTIVENESS (OEE) AND WASTE." SINERGI 22, no. 1 (February 28, 2018): 13. http://dx.doi.org/10.22441/sinergi.2018.1.003.
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In this global era where the level of competition is higher, in addition to the influence of the suitable marketing strategy is also required strategy from the side of production/productivity. PT. XYZ is a company engaged in the manufacturing of snacks especially biscuits. The problem that often occurs in this company is the number of biscuits that are not in accordance with the standard and the production does not reach the target set because the machine suddenly breaks down frequently. To overcome the problems PT. XYZ then choose to implement the Total Productive Maintenance (TPM) strategy. This study aims to evaluate the implementation of 8 TPM Pillars and measure the effects on manufacturing performance in the form of Overall Equipment Effectiveness (OEE) and Waste. This study uses questionnaire-based survey method. The number of samples distributed is 40 units. Which returned and filled 33 questionnaires and which is worth to be processed as many as 30 samples. Then tested the validity and reliability of data using SPSS program. Validity critical value R = 0.361 for n = 30 and error rate 5%. For reliability test, R value = 0.60 was selected. From the validity test, there are 7 items of questions that are not valid so it is not included in the next process. For the reliability test of the questionnaire is quite reliable with the value of Cronbach's alpha of 0.811. From the CFA analysis, only 6 of 8 TPM pillars are significant while for manufacturing performance only OEE variable is significant. Correlation between 8 Pillars of TPM and manufacturing performance is Strong enough with a value of R = 0.862, which also means 74.3% (R2) variable manufacturing performance can be explained/influenced by variable 8 Pillar TPM and 26.7% the rest by other variables.
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Sarjono, Haryadi, Edi Santoso, Endy Setiawan, and Arko Pujadi. "ANALISIS PROSES PERAWATAN MESIN DENGAN METODE TOTAL PRODUCTIVE MAINTENANCE DALAM KAITANNYA DENGAN TINGKAT DEFECT DAN BREAKDOWN YANG TINGGI PADA PT. FMI JAKARTA." Jurnal Riset Manajemen dan Bisnis 4, no. 1 (June 1, 2009): 28. http://dx.doi.org/10.21460/jrmb.2009.41.210.
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Quality in produced product become the important factor in manufacture industry competition this time. FMI company as the biggest producer whole wheat in world always tried in order to product quality that produced may satisfied consumer desire. Problem that faced by FMI company was the high defect that exceeding standard which have determined at May-June 2009'h production. After research has doni, founded that the root caused of mctchines which doesn't work optimally. Therefore, researcher feel important discussing system of machine treatment exist in FMI company. As for method which used in this research is Stotistical Process Control (SPC) method for process quality operation, and Total Productive Maintenance (TPilrI) method for treatment machine system. By using the method, researcher will look for value of process capability (cp and cpk) by using map conduct x - R, then look for value from overall Equipment Effectiveness (oEE) in production process Mill MNO. Researcher also will lookfor potential cause that caused the height defect and breakdown in Mill MNO by Failure Mode method, Effect and Criticality Analysis (FMECA).In the end a repair suggestion will be proposed by researcher in effortto lessen level of defect may reduce breakdown time that become problem of Mill MNO. Estimate writing of this skripsi may become a positive input for continuous improvementeffort that do by PT. FMI Jakarta.Keywords : quality, defect, map conduct i- n, Ong, breakdown, FMECA, continuous improvement
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Bataineh, Omar, Tarek Al-Hawari, Hussam Alshraideh, and Dorid Dalalah. "A sequential TPM-based scheme for improving production effectiveness presented with a case study." Journal of Quality in Maintenance Engineering 25, no. 1 (March 11, 2019): 144–61. http://dx.doi.org/10.1108/jqme-07-2017-0045.
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PurposeThe purpose of this paper is to improve production effectiveness of equipment by facilitating the implementation of the key principles of total productive maintenance (TPM).Design/methodology/approachA sequential TPM-based scheme consisting of 13 procedural steps is proposed. The steps cover the basic aspects of a generic improvement system, i.e. planning, implementation, checking, corrective action and control.FindingsThe proposed scheme was effective in increasing the overall equipment effectiveness by 62.6 percent over a nine-month period only. This was a direct reflection of improvements in equipment availability, efficiency and product quality. A positive feedback regarding the smooth implementation of the scheme was also received from the responsible maintenance staff.Research limitations/implicationsThe proposed scheme is intended mainly to the manufacturing industrial sector, which utilizes failure-prone equipment in running operations.Originality/valueThis study presents an original scheme that tries to avoid the many barriers of success frequently encountered during the implementation of TPM schemes, as reported in the literature. This scheme is unique in integrating between 5S and safety, health and environment initiatives, by capitalizing on the close relation between the two initiatives, and simplifying procedures for measuring how well the two initiatives are implemented in an organization in one score card. Different from previous studies, the scheme treats both “education and training” and 6S as a foundation to the core TPM principles.
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Molenda, Michał. "The Autonomous Maintenance Implementation Directory as a Step Toward the Intelligent Quality Management System." Management Systems in Production Engineering 24, no. 4 (December 1, 2016): 274–79. http://dx.doi.org/10.2478/mspe-10-04-2016.
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Abstract The article describes the effects of the improvement of the production process which one of the industrial enterprises obtained by implementing the method of Autonomous Maintenance (AM), which is one of the pillars of the concept of Total Productive Maintenance (TPM). AM method was presented as an aid to the formation of intelligent, self-improving procesess of the quality management system (QMS). The main part of this article is to present results of studies that have been conducted in one of the large industrial enterprises in Poland, manufacturing for the automotive industry. The aim of the study was to evaluate the effectiveness of the implementation of the AM method as a tool for selfimprovement of industrial processes in the following company. The study was conducted in 2015. The gathering and comparison of data from the period of two years, ie. the year before and the year after the implementation of AM, helped to determine the effectiveness of AM in building intelligent quality management system.
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Singh, Jagdeep, Harwinder Singh, and Vinayak Sharma. "Success of TPM concept in a manufacturing unit – a case study." International Journal of Productivity and Performance Management 67, no. 3 (March 5, 2018): 536–49. http://dx.doi.org/10.1108/ijppm-01-2017-0003.
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Purpose The purpose of this paper is to implement new concept of mobile maintenance in manufacturing industry of Northern India. This study tries to introduce the new concept of total productive maintenance program in the case company. Design/methodology/approach The approach is to study the role of mobile maintenance in the context of Indian industry through significant improvement in overall equipment effectiveness (OEE). Findings This industry adopted the mobile maintenance strategy and improved their productivity by decreasing breakdown time. This mobile maintenance strategy can reduce major breakdowns, setup and adjustment losses and improve productivity, product quality and OEE of equipment. Results indicate an average increase in production of 15.63 percent, average reduction in breakdown time of 23.14 percent, average reduction in rejection rate of 17.94 percent and average increase in OEE of 17.08 percent. Moreover, the results of improvements in parameters are validated by using multi-criteria decision-making approaches. Research limitations/implications Maintenance is of great importance in modern era of manufacturing systems for those organizations who consider maintenance as a profit-generating factor. In the dynamic and highly challenging environment, reliable manufacturing equipment is regarded as the major contributor to the performance and profitability of manufacturing systems. Moreover, the selection of manufacturing industry is done on the basis of convenience sampling technique. Originality/value Industry can improve machine availability and OEE by implementing this mobile maintenance concept especially in the Indian context and is very beneficially for the case company under study.
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Rahayu, Andita. "Evaluasi Efektivitas Mesin Kiln dengan Penerapan Total Productive Maintenance pada Pabrik II/III PT Semen Padang." Jurnal Optimasi Sistem Industri 13, no. 1 (April 24, 2016): 454. http://dx.doi.org/10.25077/josi.v13.n1.p454-485.2014.
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PT Semen Padang is a company that produces cement and it can not be separated from issues related to the effectiveness of the machinery/ equipment caused by factors such as six big losses. It can be indicated from the frequency of damage caused to machinery/ equipment because of the damage so that production targets are not achieved. Another result of damage caused by machinery/ equipment is the quality of products where the products are not meet the quality standards. Therefore, it is necessary to measure effective and efficient in the maintenance of machinery/equipment int term of solving such problems. TPM is a method which developed in Japan that can be applied to improve the productivity and efficiency of production. The applied method is one of useful methods to mantain machinery/equipment utilization including, losses that called by the six big losses. One goal of TPM is to increase the effectiveness to improve function and performance of machinery/ equipment used and reduce the six big losses contained in the machine/ equipment. Study has been conductedin W1 and W2 Kiln engine on Indarung Factory II / III PT Semen Padang. The first stage is measuring the effectiveness of W1 and W2 Kiln machine using OEE method. Furthermore, we are y measure OEE Six Big Losses and another losses that lead to the low efficiency of the Kiln machine. The data has been collected based on year 2013. Result showed that the value of OEE in W1 kiln ranged from 49% to 96%. While the value of OEE in W2 kiln ranged from 60% to 98% . It is related to the level of availability W1 kiln (average 92%) were also quite low when it is compared to the level of availability W2 kiln (average 94%) due to the length of time the kiln W1 engine damage. Refer to the value of the performance rate W1 and W2 kiln, it can be concluded that the average value of both engine performance rate is almost the same, ranging between 91% and 92%. Analysis of OEE Six Big Lossesshowed that cause of low OEE on kiln machine is breakdown loss. It also affected the reduced speed loss.Keyword : OEE, Six Big Losses, Availability, Performance Rate, Quality RateAbstrakPT Semen Padang merupakan sebuah perusahaan yang memproduksi semen juga tidak terlepas dari masalah yang berkaitan dengan efektivitas mesin/peralatan yang diakibatkan oleh faktor six big losses tersebut. Hal ini dapat terlihat dari frekuensi kerusakan yang terjadi pada mesin/peralatan karena kerusakan tersebut sehingga target produksi tidak tercapai. Akibat lain yang ditimbulkan kerusakan mesin/peralatan yaitu dalam hal kualitas produk yang dihasilkan dimana produk yang tidak sesuai dengan standar kualitas akan dioleh kembali. Oleh karena itu diperlukan langkah-langkah efektif dan efisien dalam pemeliharaan mesin/peralatan untuk dapat menanggulangi dan mencegah masalah tersebut. TPM adalah salah satu metode yang dikembangkan di Jepang yang dapat digunakan untuk meningkatkan produktivitas dan efisiensi produksi perusahaan dengan menggunakan mesin/peralatan secara efektif. Tidak tepatnya penanganan dan pemeliharaan mesin/peralatan tidak hanya menyebabkan masalah kerusakan saja, tetapi juga kerugian lain yang disebut dengan six big losses. Salah satu tujuan TPM adalah untuk meningkatkan efektivitas dengan cara meningktaan fungsi dan kinerja mesin/peralatan yang digunakan dan mengeliminasi six big losses yang terdapat pada mesin/peralatan. Objek yang diteliti pada penelitian ini adalah mesin Kiln W1 dan W2 yang terdapat pada Pabrik Indarung II/III PT Semen Padang. Tahapan pertama dalam usaha peningkatan efisiensi produksi pada perusahaan ini adalah dengan melakukan pengukuran efektivitas mesin Kiln W1 dan W2 dengan menggunakan metode OEE yang kemudian dilanjutkan dengan pengukuran OEE Six Big Losses dan dari faktor six big losses tersebut dicari faktor terbesar yang mengakibatkan rendahnya efisiensi mesin Kiln. Data yang digunakan adalah data satu tahun terakhir yaitu Bulan JanuariDesember 2013. Selama periode tersebut, diperoleh nilai OEE pada kiln W1 berkisar antara 49% hingga 96%. Sedangkan nilai OEE mesin kiln W2 berkisar antara 60% hingga 98%. Hal ini berhubungan dengan tingkat availability mesin kiln W1 (rata-rata 92%) yang juga cukup rendah bila dibandingkan dengan tingkat availability mesin kiln W2 (rata-rata 94%) dikarenakan lamanya waktu kerusakan mesin kiln W1. Bila dilihat dari nilai performance efficiency mesin kiln W1 dan W2, maka dapat disimpulkan bahwa nilai rata-rata performance efficiency kedua mesin ini hampir sama, yaitu berkisar antara 91% dan 92%. Bila dilakukan analisa OEE Six Big Losses, maka yang menjadi penyebab rendahnya OEE pada mesin kiln ini adalah waktu kerusakan mesin yang tergolong dalam frekuensi sering. Hal ini juga berimbas pada penurunan kecepatan kerja mesin kiln.Kata Kunci : OEE, Six Big Loss, Availability, Performance Rate, Quality Rate
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Choi Ng, Kam, and Kuan Eng Chong. "A Framework for Improving Manufacturing Overall Equipment Effectiveness." International Journal of Engineering & Technology 7, no. 3.13 (July 27, 2018): 149. http://dx.doi.org/10.14419/ijet.v7i3.13.16342.
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Nowadays, manufacturing is getting more and more challenging and complex due to shorter product life cycle, high mixed low volume production situation, low equipment performance and volatile customer demand. To overcome all these detractors and rising demands from all angles, manufacturer needs to be fast and agile, as efficient and as transparent as possible. Productivity is the key factor for company in order to become competitive advantage and securing the organization work place. Due to this strong pressure, it forces company introduce many production programs in order to fight the battle. Production productivity programs such as Total Quality Management (TQM), Zero Defect (ZD) initiative, Next Level of Productivity (NLoP), Lean Manufacturing (LM), total productive maintenance (TPM) and Toyota Production System (TPS) are well-known to many manufacturing industries. OEE topic has become progressively popular and widely used to improve productivity and as a research discussion in operation management. However, OEE framework for previous studies was developed on a piecemeal basis. This paper presents a new and complete conceptual framework that illustrates the most important factors that influence and contribute to OEE improvement. The comprehensive framework is able to provide effective guidance and direction to industry practitioner on how to improve OEE.
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Farida, Ariani, Syahputri Khalida, and Siregar Khawarita. "The Extent of Damage Identification Method Using Extrusion Machine Overall Equipment Effectiveness (OEE) in PT. XYZ." E3S Web of Conferences 73 (2018): 05003. http://dx.doi.org/10.1051/e3sconf/20187305003.
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PT. XYZ was a company that has been producing many different type of a pipe, the PVC (Poly Vinyl Chlorida) pipe, the HDPE (High Density Polyethylene) pipe and the gutters pipe that used for clean water irrigation, the pipe installation of housing complex, the industrial waste disposal, for reservoirs and telecommunication. The process of making a pipe is often hampered on an extrusive engine because it used during 24 hours a day and the maintenance schedule of the machine has not been applied regularly. We need to do identification about the damages of exstrusive machine with a Total Productive Maintenance using the Overall Equipments Effectiveness (OEE) method. From the research, it can be seen that the set up time to an extrusive machine still took a long time and the production volume of the machine was still low. The effectiveness of the performance from extrusive machine also have not been able to achieve the OEE's standard that was 88 % .
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Ningsih, Tuty, Dimas Akbar Ramadhan Lubis, and Saroha Manurung. "KAJIAN BIAYA PEMUPUKAN TANAMAN MENGHASILKAN KELAPA SAWIT (Elaeis guineensis Jacq) DI DIVISI F KEBUN SEI KALAM PT. ASAM JAWA." Jurnal Agro Estate 3, no. 2 (December 17, 2019): 97–102. http://dx.doi.org/10.47199/jae.v3i2.99.
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Fertilization in oil palm plants plays a very important role, more than 50% of the cost of the plant is used for fertilization. The hybrid oil palm currently being developed is generally very responsive to fertilization. Fertilization is a very important factor to increase the productivity and quality of the production produced. Fertilization is useful to provide nutrients needed by plants in order to carry out physiological processes that produce good growth and production. Fertilization costs are relatively high, approximately 30% of the total production costs or 40-60% of the total maintenance costs. The costs required to carry out fertilization activities are very large so that proper fertilization planning is needed to be effective and efficient. In productive plants can be done effectively 4T fertilization techniques, namely the right type, right dose, right on target, and on time. Based on this, observations were made on the study of fertilizer costs on plantations. This research was conducted in Division F of Sei Kalam Gardens, PT. Asam Jawa, Labuhanbatu Selatan Regency, North Sumatra Province. The time for the research to begin in March 2019 until May 2019.
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Punna Rao, Gunji Venkata, S. Nallusamy, P. S. Chakraborty, and S. Muralikrishna. "Study on Productivity Improvement in Medium Scale Manufacturing Industry by Execution of Lean Tools." International Journal of Engineering Research in Africa 48 (May 2020): 193–207. http://dx.doi.org/10.4028/www.scientific.net/jera.48.193.
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In current scenario, all the manufacturing industries are placing constant efforts for their endurance in the current global volatile economy. Manufacturing industries are annoying to implement new and professional techniques in their regular production processes. Some of the recognized tools are applied and their awareness has been growing among the industries, especially in production sector. Last two decades have witnessed an explosion in the area of quality and productivity improvement initiatives in the manufacturing industries by different tools and techniques such as lean manufacturing, total quality management, total productive maintenance, six sigma implementation etc. The objective of this study is to enlighten the importance of lean techniques implementation in a medium scale belt manufacturing industry. This research study helps to exhibit the existing hidden potential in the selected industry as well as a selection of appropriate techniques for productivity improvements. Also, it aims to eradicate wastes and non-value added activities at every stage in order to enhance the overall productivity. From the results after implementation of appropriate lean techniques it was found that, the lead time was reduced about 1256 minutes and the overall production was increased by about 9%.
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Smirnov, M. B., and G. B. Abdilova. "Ways of improvement of technological equipment performance." Theory and practice of meat processing 6, no. 1 (April 28, 2021): 87–96. http://dx.doi.org/10.21323/2414-438x-2021-6-1-87-96.
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Increasing of production performance of production systems and equipment in the meat-processing industry is integrally linked to maintenance activities. The article analyzes the influence of technological effectiveness, level of hygiene, reliability and simplicity of equipment design on the main parameters of meat products quality. Here it is shown that the strategy of Total Productive Maintenance (TRM) and Lean production is important tool for assessment of parameter of the Overall Equipment Effectiveness (OEE), which is used to assess the main types of losses that reduce the equipment productivity. The link of influence between the structural and mechanical properties of food masses, the moisture content of the initial food raw material, the temperature and viscosity, the processing pressure, and the density for the optimal operating terms of the equipment are analyzed in this research. With the help of OEE concept, the time losses related to the features of the equipment functioning are determined. The types of losses are classified as follows: downtime and readjustment (availability or readiness for operation) of equipment, short-term shutdown of equipment and a decrease in processing speed (productivity or performance rate of the equipment), product rejects and product losses (quality losses) during startup of equipment. While analyzing of the operation of vacuum filler for sausages production, the values of parameters of equipment availability, it productivity and product quality are calculated. The availability index is 0.79, the productivity index is 0.76, and the product quality index is 0.95. Taking into account the obtained data on equipment availability, productivity and product quality, it is determined that the overall equipment effectiveness (OEE) accounts for 57%. The application of this method for studying the overall equipment effectiveness operation can be applied to any technological equipment used in the meat-processing industry and allows eliminating many problems that arise during the operation of technological equipment, improving its technical and economic parameters, and developing a system of measures for improvement of its maintenance and repair.
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Modi, Vinitkumar Kiritkumar, and Darshak A. Desai. "Status of Six Sigma and Other Quality Initiatives in Foundries Across the Globe." International Journal of Applied Industrial Engineering 4, no. 1 (January 2017): 65–84. http://dx.doi.org/10.4018/ijaie.2017010104.
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Foundries are actively involved to reduce the scrap rejection and rework during the manufacturing process of the components and improving their sigma level. In 2014, global casting production in foundries are increased to more than 105 million metric tons, an increase of 2.3%, according to this year's MODERN CASTING Census of World Casting Production. This all papers discus various tools and techniques used in various phases of DMAIC like a ANOVA, process map, the cause effect matrix diagram, statistical methods, SQC, design of experiments (DoE) and Taguchi methods Fuzzy Analytic Hierarchy Process(FAHP) Total Productive Maintenance (TPM) which used by various foundries of world to enhance their manufacturing performance. Defect reduction is therefore chosen as the Critical-to- Quality (CTQ) factor, for world class quality in foundry products. Analysis is carried out using various software like Minitab, SPSS, and SPC for Excel etc. Study shows Six Sigma is a well-structured methodology to achieve expected goal which is need of the day in globally competitive era.
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Sousa, Juliana Valença, Fagner José Coutinho de Melo, Joás Tomaz de Aquino, and Taciana De Barros Jerônimo. "USING AHP TO IMPROVE MANUFACTURING PROCESSES IN TPM ON INDUSTRIAL AND PORT COMPLEX." Exacta Volume 19, Issue 3 (March 18, 2021): 523–49. http://dx.doi.org/10.5585/exactaep.2021.16693.
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This paper aimed to develop a model to rank the critical factors for the improvement of the production process from the point of view of Total Productive Maintenance (TPM) in six companies located in the Suape Industrial Complex region. The work was classified as applied research, qualitative and quantitative, exploratory and descriptive, and study of case. The proposed model developed used the Analytic Hierarchy Process (AHP) method using six criteria: Equipment Breakdown, Long Setup, Small Stops, Reduction in Speed, Defective Production, Start-up. The results showed that all the six criteria were considered as critical increment factors for improvement from the TPM and the decision-maker, and the factors that contributed the most were long setup and breakdown of equipment with almost 50%. The study's contribution is developing a model that allows the possibility of a classificatory grouping of critical factors to increase improvement, from the point of view of the TPM and the decision-maker.
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Haradito, Aditya, Iman Sabarisman, and Satria Bhirawa Anoraga. "Analisis Efektivitas Mesin pada Divisi Pengalengan Jamur Di PT. Suryajaya Abadiperkasa Menggunakan Metode Overall Equipment Effectiveness." Jurnal Nasional Teknologi Terapan (JNTT) 3, no. 1 (June 29, 2020): 87. http://dx.doi.org/10.22146/jntt.56619.
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PT Suryajaya Abadiperkasa is a food canning industry. Nowadays, many companies are looking up for the alternatives to increase the company revenue by making a continous improvement in every process. This study has three aims to be achieved. First, knowing the value of availability rate, performance rate, and quality rate. Second, to determine the major cause which affecting the effectiveness value of the production machine. Third, to obtain the alternatives improvement to increase the machine effectivity. Overall Equipment Effectiveness (OEE) is a method to determine the effectiveness level of equipment utilization. The OEE method is known as one of the program applications of Total Productive Maintenance (TPM). This study measures the value of OEE in the production line of mushroom canning within two months. The values of this study are, availability rate is 89.99%, performance rate is 65.13%, and quality rate is 99.76%. From those data, the obtained calculation value of OEE is 58.71%, it shows that it has not reach yet the best practice (85%) and need an improvement. The Losses in PT Suryajaya Abadiperkasa are breakdown losses, setup and adjustment losses, idle and minor stoppage losses, and defect losses. The alternatives improvement are tightening the maintenance schedule, as well as inspection before and after use on the machine. This maintenance is supported by a focus on the TPM pillar of self-improvement, which changes the workers’ mindset, to change the mindset of the workers there should be an education and training to improve the ability of workers.
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Satolo, Eduardo Guilherme, Caroline Leite, Robisom Damasceno Calado, Gustavo Antiqueira Goes, and Douglas D’Alessandro Salgado. "Ranking lean tools for world class reach through grey relational analysis." Grey Systems: Theory and Application 8, no. 4 (October 8, 2018): 399–423. http://dx.doi.org/10.1108/gs-06-2018-0031.
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Purpose The lean production system and world class manufacturing (WCM) have been prominent in recent studies due to their conceptual synergy. However, although the number of studies is increasing, the research is immature, especially regarding the interaction between topics. Therefore, the purpose of this paper is to rank the tools of the lean production system, indicating how they help organizations achieve WCM, using the theory of grey systems. Design/methodology/approach Therefore, the authors conducted an initial survey to collect data to determine how the lean production tools are related to the WCM pillars. These data were analyzed by the grey relational analysis statistical method, which passes through the construction of four stages. Findings The results show that of the lean production tools, stream mapping, kaizen, total productive maintenance, Six Sigma, standardized work and 5S stand out for their use and implementation in the organizational environment and facilitate organizations’ transitions to world-class performance through the WCM pillars. Practical implications The results achieved guide organizations to use the tools of the lean production system to help them reach world class status. Originality/value This paper stands out in the field of operations management, specifically in the research on lean production, by making use of the theory of grey correlation system in an innovative and original way. In addition, it promotes the consolidation of information on two of the main administrative strategies currently employed in the organizational environment.
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Ahmad, Mohd Fauzi, Norhayati Zakuan, Ahmad Jusoh, Shari Mohd Yusof, Josu Takala, and Mohd Shoki Md Arif. "Comparative Study of TQM Practices between Japanese and Non-Japanese Companies: Proposed Conceptual Framework." Advanced Materials Research 903 (February 2014): 371–77. http://dx.doi.org/10.4028/www.scientific.net/amr.903.371.
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In todays highly competitive market, the demand for quality is a critical factor for organization to survive in the ever-expanding global marketplace. The concept of total quality management (TQM) has been developed as a result of intense global competition. Japanese companies have had superior achievement, and left their counterparts, non-Japanese far behind. One of the TQM strength practices in Japanese companies is technical aspects; tools and techniques namely statistical process control (SPC), total productive maintenance (TPM) and lean production. The purpose of this paper is to compare TQM practices between Japanese and non-Japanese companies, and develop the conceptual framework based on extensive review of the literature. Three theories; institutional theory, system theory and contingency theory have been identified and applied in this study for developing conceptual framework. Based on literature review, Japanese companies have higher TQM practices compared to non-Japanese companies. Furthermore, this study proposes that SPC, TPM and lean production are mediators for TQM in Japanese companies. This proposed research will help the academicians and industry players to have better understanding of TQM implementation in order to improve business performance effectively in the future.