Total Productive Maintenance (TPM) Implementation in Foundry

Abstract

This dissertation illustrates the Total Productive Maintenance (TPM). It is the manufacturing improvement method that increases production and reduces waste through continuous attention to the condition of machines and processes.

In this work a scheme of OEE calculation is developed for the foundry. Monthly data available from the foundry is analyzed. Pareto analysis is carried out to identify the factors most responsible for the lower quality rate of the foundry. Also Pareto analysis is carried out to identify the reasons having maximum impact on downtime of equipment. Cause and Effect analysis is carried out to identify the factors responsible for occurrence of three major defects. Action plan is prepared for reducing Sand Drop, Blow Hole, & Lug Variation defect. As a part to improve productivity and quality, suggestion scheme is developed and one Kaizen project is carried out.