Improvement of Overall Equipment Effectiveness (OEE) using TPM in Industries

Total Productive Maintenance has been proven to be a very effective tool for the improvement of productivity and efficiency of employees and equipments. From the TPM perspective reliability and availability are the ultimate goals. The way to accomplish the goals is through elimination of major losses. These losses are only due to mechanical nature and visualized by key figure OEE. In this paper, the study of OEE improvement in Printing Industries Ltd is discussed. During this study, The 11 CNC machines were considered for the first phase of TPM implementation. The study of the old setup of machine shop of the company was done to find out different drawbacks and barriers. It was observed that machine shop has less OEE, lack of self improvement of operator, strong resistance to change by operators, improper use of resources, and poor arrangement system of tools. It was decided to use TPM tools to eliminate the above problems and to improve the OEE. The TPM plan was executed by using different methodologies. Machine performance data were collected for 11 machines under consideration after TPM implementation. These data were used for comparison of utilization time, idle time, efficiency and OEE of the 11 machines before and after TPM activity. During implementation of TPM various tools were used such as 5S, Autonomous maintenance, Preventive maintenance and Focus improvement (SMED). All methodologies contributed to increase utilization time and OEE of machines in different manners. The result of this work is increase in utilization time and decrease in idle time by 5% and 3% respectively as compare to old machine setup. Thus average OEE of 11 machines reaches to 72.56% which shows 3.26% increase than the previous year.