Service Incident: New DOI registrations are working again. Re-registration of failed DOI registrations (~500) are still affected by the service incident at DataCite (our DOI registration agency).
Published January 20, 2010 | Version 8081
Journal article Open

Improvement of Overall Equipment Effectiveness through Total Productive Maintenance

Description

Frequent machine breakdowns, low plant availability and increased overtime are a great threat to a manufacturing plant as they increase operating costs of an industry. The main aim of this study was to improve Overall Equipment Effectiveness (OEE) at a manufacturing company through the implementation of innovative maintenance strategies. A case study approach was used. The paper focuses on improving the maintenance in a manufacturing set up using an innovative maintenance regime mix to improve overall equipment effectiveness. Interviews, reviewing documentation and historical records, direct and participatory observation were used as data collection methods during the research. Usually production is based on the total kilowatt of motors produced per day. The target kilowatt at 91% availability is 75 Kilowatts a day. Reduced demand and lack of raw materials particularly imported items are adversely affecting the manufacturing operations. The company had to reset its targets from the usual figure of 250 Kilowatt per day to mere 75 per day due to lower availability of machines as result of breakdowns as well as lack of raw materials. The price reductions and uncertainties as well as general machine breakdowns further lowered production. Some recommendations were given. For instance, employee empowerment in the company will enhance responsibility and authority to improve and totally eliminate the six big losses. If the maintenance department is to realise its proper function in a progressive, innovative industrial society, then its personnel must be continuously trained to meet current needs as well as future requirements. To make the maintenance planning system effective, it is essential to keep track of all the corrective maintenance jobs and preventive maintenance inspections. For large processing plants these cannot be handled manually. It was therefore recommended that the company implement (Computerised Maintenance Management System) CMMS.

Files

8081.pdf

Files (220.1 kB)

Name Size Download all
md5:ab9d65af05942f084d1a941f7adfa315
220.1 kB Preview Download

Additional details

References

  • M. Ahmad and R. Benson, Benchmarking in the process Industry, Institution of Chemical Engineers,2007, UK.
  • Moubray, J. Reliability-Centered Maintenance II, 2nd Edition, Butterworth-Heinemann, 1997, Oxford.
  • A.H.C. Tsang, A.K.S. Jardine, H. Kolodny, ÔÇÿMeasuring maintenance performance: a holistic approach-, International Journal of Operations & Production Management, Vol. 19 No.7, pp.691-715, 1999.
  • J. Moubray, Reliability-Centered Maintenance II, 2nd Edition, Butterworth-Heinemann, 1997,Oxford.
  • Kelly, A.1997. Maintenance Organisation & Systems - Business- Centred Maintenance, Butterworth-Heinemann, Oxford.
  • K.Y. Kutucuoglu, J. Hamali, I. Iran, and J.M. Sharp, ÔÇÿA framework for managing maintenance using performance measurements systems-, International Journal of Operations & Production Management, Vol. 21 No.1, pp.173-95, 2001.
  • A. Raouf, M. Ben-Daya,"Total maintenance management: a systematic approac," Journal Of Quality in Maintenance Engineering. 1995.Vol.1:1 pg 6-14, 1995.
  • D.J. Smith, "Reliability, Maintainability and risk: Practical Methods for Engineers including RCM and Safety-Related Systems", Butterworth Heinemann,2005.
  • Mishra,P. R., Anand, D. and Kodali, R. 2006. "Development of a framework for world-class maintenance systems", Journal of Advanced Manufacturing Systems, Vol. 5, No.2, pp.141-65. [10] A. C. Ma'rquez, P. Moreu de Leo'n, J.F. Go'mez Ferna'ndez, C. Parra, and M. Lo'pez Campos, 'A practical view to maintenance management-, Journal of Quality in Maintenance Engineering Vol. 15 No. 2, pp. 167- 178,2009 [11] C.A. Schuman, and A.C. Brent, "Asset life Management: towards improving physical asset performance in the process industry", International journal of Operations and Production Management. Vol.25, No.6 pp. 566-579, 2005). [12] D. Koshal, Manufacturing Engineer-s Handbook, Butterworth Heinemann, 1993.