study of implementation of total … maintenance in textile . machine manufacturing industries ....
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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%
Scheduled time (ST) = 12 hrs
Operating time (OT) = ST–Lunch break
time- ideal time = 12-1-2 = 9 hrs
• Availability (A)= 75%
• Quality (Q) = 100%
Ideal cycle time = 2 units/hr
• Performance efficiency (PE)= 60%
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 180
OEE = (75*96*60)/100000 = 43.2% OEE = (75*100*60)/100000 = 45%
EXO-CUTTING 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- breakdown time
= 12-1-1-0.5 = 9.5 hrs
• Availability (A)= 79%
• Quality (Q) = 98%
Ideal cycle time = 3 mins/unit
• Performance efficiency (PE)= 60%
OEE = (79*98*60)/100000 = 46.4%
Scheduled time (ST) = 12 hrs
Operating time (OT) = ST–Lunch break
time- ideal time- breakdown time
= 12-1-1-0.5 = 9.5 hrs
• Availability (A)= 79%
• Quality (Q) = 100%
Ideal cycle time = 3 mins/unit
• Performance efficiency (PE)= 60%
OEE = (79*100*60)/100000 = 47.4
LATHE MACHINE (BIG HOLE DRILLING) (58mm)
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) = 99%
Ideal cycle time = 12mins/unit
• Performance efficiency (PE)= 60%
OEE = (75*99*60)/100000 = 44.5%
Scheduled time (ST) = 12 hrs
Operating time (OT) = ST–Lunch break
time- ideal time = 12-1-2 = 9 hrs
• Availability (A)= 75%
• Quality (Q) = 100%
Ideal cycle time = 12mins/unit
• Performance efficiency (PE)= 60%
OEE = (75*100*60)/100000 = 45%
LATHE MACHINE (BORING OPERATION) (108mm)
Data collected before TPM
implementation:-
Data collected after TPM
implementation:-
Scheduled time (ST) = 12 hrs
Operating time (OT) = ST–Lunch break
time- ideal time = 12-1-1 = 10 hrs
• Availability (A)= 75%
• Quality (Q) = 99%
Ideal cycle time = 1hr/unit
• Performance efficiency (PE)= 100%
OEE = (75*99*100)/100000 = 74.2%
Scheduled time (ST) = 12 hrs
Operating time (OT) = ST–Lunch break
time- ideal time = 12-1-1 = 10 hrs
• Availability (A)= 75%
• Quality (Q) = 100%
Ideal cycle time = 1hr/unit
• Performance efficiency (PE)= 100%
OEE = (75*100*100)/100000 = 75%
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 181
SLOTTING MACHINE (KEY)
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-.5 = 8.5 hrs
• Availability (A)= 70%
• Quality (Q) = 99%
Ideal cycle time = 30min/unit
• Performance efficiency (PE)= 60%
OEE = (70*99*60)/10000 = 41%
Scheduled time (ST) = 12 hrs
Operating time (OT) = ST–Lunch break
time- ideal time = 12-1-2-.5 = 8.5 hrs
• Availability (A)= 70%
• Quality (Q) = 99%
Ideal cycle time = 30min/unit
• Performance efficiency (PE)= 60%
OEE = (70*100*60)/10000 = 42%
HISTOGRAM CHART
Figure-1 Before implementing TPM
Figure-2 After implementing TPM
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 182
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.
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 183