Evaluation of Total Productive Maintenance Implementation in a Selected Semi-Automated Manufacturing Industry

Manufacturing industries around the world spend a lot of money on buying new equipment to increase production but a little is done to get hundred percent output from the machine. However, because of increased competency levels 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 general, implementing an appropriate maintenance strategy has become increasingly important for manufacturing companies to accomplish these requirements. 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. Performance evaluation is the most important aspects in the field of continuous improving of the production process and overall equipment effectiveness (OEE) is one of the justified performance evaluation methods that is popular in the manufacturing industries to assess the machine's effectiveness and performance. In this concern, this research work has been conducted in a selected semi-automated manufacturing industry to study and evaluate the implementation of autonomous maintenance and planned maintenance pillars of TPM. After the OEE measurement, it has been benchmarked with the world class OEE. Pareto and statistical analysis of downtimes were performed to show the most affecting downtime factors hierarchically. Based on the obtained results, maintenance management and production planning have been suggested to improve their maintenance procedures and the productivity as well.