Framework for total productive maintenance for an SME
Abstract
Total Productive Maintenance (TPM) is a worldwide maintenance program for plant equipment and machinery. It is a proactive maintenance that optimizes Overall Equipment Effectiveness (OEE) to get rid of the six (6) big losses. The research was inspired by observations made over a six (6) months period at Company X, a Small and Medium Enterprise (SME). Observations made were that the SME produced a lot of defective items, some requiring reworks, the SME had poor maintenance plans, poor relationship between departments, resulting in low morale of workers, frequent breakdowns of machines, as well as low production rate. The main objective of the research was to design a framework that would identify and address the aforementioned problems, resulting in an optimized OEE rate. The research data was obtained through various methodologies, including observation, questionnaire as well as interviews among the company employees - technicians, operators, and maintenance engineers. The data was analysed using Microsoft excel performance dashboards as well as TPM templates. Based on the findings, a framework was designed and developed that sought to address the aforementioned problems at the company. The study improved the OEE of machines and processes through the implementation of TPM approach at Company X.
Downloads
References
E. de Souza, M. Fortes, and G. de Lima, “Application based on fuzzy logic to evaluate implementation of TPM in industries”, JETIA, vol. 6, no. 22, pp. 35-41, Apr. 2020.
N. E. Candra, A. Susilawati, and W. Setiady, “Implementation of total productive maintenance (TPM) to improve sheeter machine performance”, In MATEC Web of Conferences 2017, Vol. 135, p. 00028). EDP Sciences.
A. Shagluf, A. P. Longstaff, S. Fletcher, “Maintenance strategies to reduce downtime due to machine positional errors”, InProceedings of Maintenance Performance Measurement and Management (MPMM) Conference 2014. Imprensa da Universidade de Coimbra.
O. M. Enofe and G. Aimienrovbiye, “Maintenance impact on production profitability-A case study”, 2010.
Villegas, L., & Velez, A. (2014). Implantation of Total Productive Maintenance-TPM-scenarios of corporative fusion. 12th Latin American and Caribbean Conference for Engineering and Technology. “Excellence in Engineering to Enhance a Country’s Productivity”. Guayaquil, Ecuador.
Matos, R. (2012). Development of a Total Productive Maintenance (TPM) Program in the Special mixture’s area of a Miller. Faculty of Engineering Industry. “Engineering Magazine”, 19(3), 66.
Reyes, J., Alvarez, K., Martínez, A., & Guamán, J. (2018). Total productive maintenance for the sewing process in footwear. Journal of Industrial Engineering and Management, 11(4), 814-822. https://doi.org/10.3926/jiem.2644
S. Sahoo and S. Yadav, “Influences of TPM and TQM Practices on Performance of Engineering Product and Component Manufacturers”, Procedia Manufacturing, vol. 43, pp. 728-735, Jan. 2020.
Sharma R, Singh J, Rastogi V. The impact of total productive maintenance on key performance indicators (PQCDSM): a case study of automobile manufacturing sector. International Journal of Productivity and Quality Management. 2018;24(2):267-83.
Diky Herdiawan, Erry Rimawan,. (2020). ANALYSIS OF THE PILAR TPM EFFECT ON PRODUCTIVITY TO IMPROVING THE COMPETITIVENESS OF TEXTILE INDUSTRIES IN INDONESIA. International Journal of Advanced Science and Technology, 29(7s), 5256-5268. Retrieved from http://sersc.org/journals/index.php/IJAST/article/view/25933
Wakjira, M. W., & Singh, A. P. (2012). Total productive maintenance: A case study in manufacturing industry. Global Journal of Research in Engineering, 12(1-G).
Ahuja, I.P.S. and Khamba, J.S. (2008), “Total productive maintenance: literature review and directions”, International Journal of Quality & Reliability Management. Vol. 25 No. 7, 2008 pp. 709-756. DOI 10.1108/02656710810890890
I. Idris and R.A.Sari. Implementation of eight pillars the Total Productive Maintenance at Water Supply Company, in proceedings of 1st International Joint Conference Indonesia-Malasya-Bangladesh-Ireland, 2015.
Georgescu D, Constantin M. 7s's system foundation of total productive maintenance house for lean organization. Scientific Bulletin of the" Petru Maior" University of Targu Mures. 2009;6:131.
Joshi, A. A., 2015. A Review on Seven S (7S) as a tool of Workplace Organization. International Journal of Innovations in Engineering and Technology (IJIET), 6(2), pp. 19-25.
Mahlaha, K., Sukdeo, N. & Mofokeng, V., 2020. A Lean 7S methodology framework to improve efficiency and organizational performance: A review study in an SME organization. Dubai, UAE, International Conference on Industrial Engineering and Operations Management.
Muchiri, P., & Pintelon, L. (2008). Performance measurement using overall equipment effectiveness (OEE): literature review and practical application discussion. International journal of production research, 46(13), 3517-3535.
Borkowski, S., Czajkowska, A., Stasiak-Betlejewska, R., & Borade, A. B. (2014). Application of TPM indicators for analyzing work time of machines used in the pressure die casting. Journal of Industrial Engineering International, 10(2), 1-9.
Nakajima, S., (1988) Introduction to Total Productive Maintenance, Productivity Press Inc, Portland, p.21.
Sethia, C. S., Shende, P. N., & Dange, S. S. (2014). Total productive maintenance-a systematic review. International journal for scientific research & development (8), 124-127.
Filscha N, Meilily A, Hendy T. Total productive maintenance policy to increase effectiveness and maintenance performance using overall equipment effectiveness. Journal of Applied Research on Industrial Engineering. 2019;6(3):184-99.
Khan, F.J., & Quazi, T.Z. (2014). Implementation of Kobetsu Kaizen pillar in Improving Overall Equipment Effectiveness of Machine. International Journal of Engineering Sciences & Research Technology, 3(7), 562-570.
Prabowo HA, Suprapto YB, Farida F. The evaluation of eight pillars total productive maintenance (TPM) implementation and their impact on overall equipment effectiveness (OEE) and waste. Sinergi. 2018;22(1):13-8.
Ljungberg, O. (1998), “Measurement of overall equipment effectiveness as a basis for TPM activities”, International Journal of Operations & Production Management, Vol. 18 No. 5, pp. 495-507.
Dal, B., Tugwell, P. and Greatbanks, R. (2000), “Overall equipment effectiveness as a measure for operational improvement: a practical analysis”, International Journal of Operations & Production Management, Vol. 20 No. 12, pp. 1488-502.
Tsarouhas, P. (2019). Improving operation of the croissant production line through overall equipment effectiveness (OEE). International Journal of Productivity and Performance Management, 68(1), 88-108. https://doi.org/10.1108/IJPPM-02-2018-0060
Tian Xiang, Z,, & Jeng Feng, C. (2021). Implementing total productive maintenance in a manufacturing small or medium-sized enterprise. Journal of Industrial Engineering and Management, 14(2), 152-175. https://doi.org/10.3926/jiem.3286
Singh, R.K., Clements, E.J., & Sonwaney, V. (2018). Measurement of overall equipment effectiveness to improve operational efficiency. International Journal of Process Management and Benchmarking, 8(2), 246-261. https://doi.org/10.1504/IJPMB.2018.090798
Garza-Reyes, J.A., Eldridge, S., Barber, K.D., & Soriano-Meier, H. (2010). Overall equipment effectiveness and process capability measures. International Journal of Quality & Reliability Management, 27(1), 48-62. https://doi.org/10.1108/02656711011009308
P. Gupta and S. Vardhan, “Optimizing OEE, productivity and production cost for improving sales volume in an automobile industry through TPM: a case study”, International Journal of Production Research, vol. 54, no.10, pp. 2976-2988, 2016.
K. M. Joshi and D. V. Bhatt, “A modified TPM framework for Indian SMEs”, International Journal of Advanced Research in Engineering and Technology, vol. 9, no. 6, pp. 1-14, Nov. 2018.
S. C. Nwanya, J. I. Udofia, and O. O. Ajayi, “Optimization of machine downtime in the plastic manufacturing”, Cogent Engineering, vol. 4, no. 1, pp. 1335444, Jan. 2017.
This work is licensed under a Creative Commons Attribution 4.0 International License.
