Abstract:

The current levels of competition makes the organizations to continually strive to meet the customer demand but it has been observed that due to problems like machine breakdown, machining and setting process delays it has become difficult in meeting this on time. The objective of this article is to inspect the manufacturing losses arising on account of such problems by prioritizing the root causes with the help of a pareto diagram and finally suggesting the solution to overcome these problems. A case study was carried out to improve the utilization of machine tool and manpower by initiating the practices through, TPM that would also form as a base for lean manufacturing. TPM helps to adopt a systematic work inside the shop floor which reduces the losses in production activity, increases the equipment life, ensures effective utilization of equipments and organized employee behavior. Introduction of new fixture reduces the idle time of machine during component setting and achieving cycle time reduction by analyzing cutting tool and its parameters which helps to increase the output to meet the customer demand. From the final results, it was observed that there was reduction in setup time, cycle time, breakdown losses and rework time, while the overall equipment effectiveness was also found to have increased by about 15%.