Assessment of total productive maintenance implementation in a semiautomated manufacturing company through downtime and mean downtime analysis

Total productive maintenance (TPM) has become one of the most popular maintenance strategies to ensure high machine reliability since it is regarded as an integral part of lean Manufacturing. One of the main objectives of TPM is to increase the overall equipment effectiveness of plant equipment with a modest investment in maintenance. Companies around the world spend a lot of money on buying new machinery to increase the production, however a little is done to get hundred percent output from the machines. Nevertheless, because of increased competition and demand of quality products at lower costs, buying latest equipment is not a solution unless it is fully utilized. Therefore machine maintenance and in particular, implementing an appropriate maintenance strategy has become increasingly important for manufacturing industries to fulfill these requirements. In this regard, this paper has focused on a case-study work with the aim of evaluating the effects of total productive maintenance implementation onto the existing production scenario of a selected semi-automated manufacturing company of Bangladesh by measuring downtime and mean downtime reduction and performing mean downtime analysis (MDT). Pareto analysis and statistical analysis of downtimes have been conducted to identify the most affecting downtime factors hierarchically. According to the results observed, modern maintenance management and production improvement techniques have been suggested to improve the maintenance procedure and at the same time to enhance the volume of production as well.