Enhancement of Overall Equipment Effectiveness using Total Productive Maintenance in a Manufacturing Industry
Volume 13, Number 2, March 2017 - Paper 7 - pp. 173-188
S. NALLUSAMY1* and GAUTAM MAJUMDAR2
1Professor and Dean, Department of Mechanical Engineering, Dr. M G R Educational and Research Institute, Chennai, 600095, Tamilnadu, India
2Professor, Department of Mechanical Engineering, Jadavpur University, Kolkata-032
(Received on October 25, 2016, Revised on January 18, 2017)
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%.
 Arunraj, K., and M. Maran.A Review of Tangible Benefits of TPM Implementation. International Journal of Applied Sciences and Engg. Research, 2014; 3(1): 171-176.
 Patel, V.B., and H. R. Thakkar. Review Study on Improvement of Overall Equipment Effectiveness through Total Productive Maintenance. Journal of Emerging Technologies and Innovative Research, 2014; 1(7): 720-726.
 S. Nallusamy.Enhancement of Productivity and Efficiency of CNC Machines in a Small Scale Industry using Total Productive Maintenance. International Journal of Engineering Research in Africa, 2016; 25: 119-126.
 I.H. Afefy. Implementation of Total Productive Maintenance and Overall Equipment Effectiveness Evaluation. International Journal of Mechanical & Mechatronics Engineering, 2013; 13(1): 69-75.
 S. Nallusamy. Productivity Enhancement in a Small Scale Manufacturing Unit through Proposed Line Balancing and Cellular Layout. International Journal of Performability Engineering, 2016; 12(6): 523-534.
 M.K. Panneerselvam. TPM Implementation to Invigorate Manufacturing Performance: An Indian Industrial Rubric. International Journal of Scientific & Engineering Research, 2012; 3(6): 1-10.
 S. Nallusamy. Lean Manufacturing Implementation in a Gear Shaft Manufacturing Company using Value Stream Mapping. International Journal of Engineering Research in Africa, 2015; 21: 231-237.
 Keyser, R.S., and R.S. Sawhney.Reliability in Lean Systems. International Journal of Quality and Reliability Management, 2013; 30(3): 223-238.
 Kumar, S.V.,V.G. Mani, and N. Devraj. Production Planning and Process Improvement in an Impeller Manufacturing using Scheduling and OEE Techniques. Procedia Materials Science, 2014; 5: 1710-1715.
 S. Nallusamy. Frequency Analysis of Lean Manufacturing System by Different Critical Issues in Indian Automotive Industries. International Journal of Engineering Research in Africa, 2016; 23: 181-187.
 Arunraj, K. and M. Maran. A Review of Tangible Benefits of TPM Implementation. International Journal of Applied Sciences and Engg. Research, 2014; 3(1): 171-176.
 Samad, M.A., and M.R. Hossain. Analysis of Performance by Overall Equipment Effectiveness of The CNC Machine. APRN J. of Sci. and Tech., 2012; 2(11): 1091-1096.
 S. Nallusamy. Efficiency Enhancement in CNC Industry using Value Stream Mapping, Work Standardization and Line Balancing. International Journal of Performability Engineering, 2016; 12(5): 413-422.
 Puvanasvaran, A.P., C.Z. Mei, and V.A. Alagendran. Overall Equipment Efficiency Improvement using Time Study in an Aerospace Industry. Engineering Procedia Journal, 2013; 68: 271-277.
 Nallusamy, S.,G.B. Dinagaraj, K. Balakannan, and S. Satheesh. Sustainable Green Lean Manufacturing Practices in Small Scale Industries -A Case Study. International Journal of Applied Engineering Research, 2015; 10(62):143-146.
 Kumar, S.V., V.G. Mani, and N. Devraj. Production Planning and Process Improvement in an Impeller Manufacturing using Scheduling and OEE Techniques. Procedia Materials Science, 2014; 5: 1710-1715.
 Low, S.N., S.H. Chong, H.Y. Sim, S. Razalli, and S. Kamaruddin. Measurement of Overall Performance Effectiveness in Setup Improvement. Journal of Industrial Engineering, 2014; 2014: 1-7.
 O.T.R. Almeanazel. Total Productive Maintenance and Overall Equipment Effectiveness Measurement. Jordan Journal of Mech. and Ind. Engg, 2010; 4(4): 517-533.
 S. Nallusamy. A Proposed Model for Lead Time Reduction During Maintenance of Public Passenger Transport Vehicles. International Journal of Engineering Research in Africa, 2016; 23:174-180.
 Mori, Vipulkumar V., Y.B. Kanchava, P.A. Karetha, and M.B. Charola.Productivity Improvement by use of Time Study, Motion Study, Lean Tools and Different Strategy for Assembly of Automobile Vehicles. International Journal for Scientific Research and Development, 2015; 3(2): 2060-2065.
 S. Nallusamy.A Proposed Model for Sustaining Quality Assurance using TQM Practices in Small and Medium Scale Industries. International Journal of Engineering Research in Africa, 2016; 22: 184-190.
 Gabahne, L.D., M.M. Gupta, and D.R. Zanwar. Overall Equipment EffectivenessImprovement: A Case of Injection Molding Machine. The International Journal of Engineering and Sci., 2014; 3(8): 01-10.
 Sahu, S., L. Patidar, and P.K.Soni.5S Transfusion to Overall Equipment Effectiveness (OEE) for Enhancing Manufacturing Productivity. International Research Journal of Engineering and Technology, 2015; 2(7): 1211-1216.
 Nallusamy, S., and V. Saravanan. Enhancement of Overall Output in a Small Scale Industry through VSM, Line Balancing and Work Standardization. International Journal of Engineering Research in Africa, 2016; 26: 176-183.
Please note : You will need Adobe Acrobat viewer to view the full articles.