OEE—A tool for Implementation Of TPM—A Case Study

Abstract

The increased dependence on the production equipment to reliably and repeatedly manufacture high quality products has created the need for a new approach to equipment management. Total Productive Maintenance (TPM) is an effective method for addressing this equipment management challenge. Forging Companies are currently undertaking a metamorphosis in order to become more competitive in the commercial market. A large component of this change is an effort to improve manufacturing capabilities and reduce waste, which reduce overall production costs. To accomplish these goals, any forging company must improve both the quality of their products and the reliability of their production equipment. The implementation of Total Productive Maintenance (TPM), in the proper environment, can provide on an effective set of processses to drastically improve their manufacturing effectiveness through more reliable production equipment. An effort was made to implement some principles of TPM in a forging industry. This paper presents how the Overall Equipment Effectiveness (OEE) is measured in the forge shop and how a computer program developed helps to find out systematic stoppage analysis & OEE of hammer and other forging equipments. By considering shift data, number of good products, rejection, rework and reason for break down, OEE is calculated and a report is automatically generated and updated. By implementing TPM in these situations, the down time (manufacturing costs) associated with six big losses (variability in both product quality and production schedules) can be reduced and OEE can also be improved. By analyzing the results, conclusions have been drawn and suggestions for further scope for future work have been provided.