IMPROVING OVERALL EQUIPMENT EFFICTIVENESS BY APPLYING TPM- A CASE OF DETERGENT MANUFACTURING FACTORY

Abstract

Overall Equipment Effectiveness (OEE) is the measurement of machine Effectiveness where right quality and right delivery at a right time are the major factor. The purpose of this paper is to enhance the Overall Equipment Effectiveness (OEE) by implementing TPM techniques such as 5s, KAIZEN, autonomous maintenance. The current goal is to increase the machine Effectiveness, quality rate and decrease the machine breakdown. The OEE is calculated in three aspects machine performance, machine availability and quality. Here amongst the six machines in the packaging area the Bosch 500g machine had the lowest machine Effectiveness. So here the Bosch 500 g machine has been considered. The previous data of the machine shows that the performance Effectiveness was 75.95%, the availability was 75.57%, and the product quality rate of the machine was 75%. The obtained overall equipment Effectiveness (OEE) was 43.072% which is below standard in present scenario. The breakdown time of the machine per day was quite large. After implementation of various TPM techniques such as 5s, autonomous maintenance, KAIZEN, the breakdown time of the machine was reduced. The KAIZEN helps to modify the machine equipment. The autonomous maintenance helps to provide adequate training to machine operator to learn about the operational function of the machine so that they can handle small breakdown problem. By autonomous maintenance operators are quite concerned about the maintenance schedule. After implementing such of this technique the breakdown time is reduced and the time is 85 minutes where before implementation of TPM the time was 145 minutes. The performance Effectiveness of the machine is also increased from 75.95% to 90.63%, the availability increased from 75.57% to 88.0%, the quality rate increased from 75% to 79%. After calculating the value of performance, availability and product quality, the obtained overall equipment Effectiveness (OEE) is 63.006% which is larger than the previous OEE.