Implementation Of TPM In A Forging Unit – 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 units 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 wastage, which reduce overall production costs. To accomplish these goals, any forging unit must improve both the quality of their products and the reliability of their production equipments. The implementation of Total Productive Maintenance (TPM), in the proper environment, can provide effective set of processes to drastically improve their manufacturing effectiveness through more reliable production equipments. A case study was carried out in a typical SME forging unit in Gujarat which currently does not have a reliable and repeatable methodology for implementing TPM. The intent of case study was to establish an effective approach for implementing TPM. This paper explains the methodology of the measurement of Overall Equipment Effectiveness (OEE) in the forging unit shops. A computer software was developed to help the organization to find out the systematic stoppage analysis & OEE of hammer and other forging equipments. By considering shift data, consisting of number of acceptable products, rejection, rework and reason for break down, OEE could be calculated and report can be automatically generated and updated. Also this paper contains methodology of TPM implementation in the forging unit. 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 be improved. The paper shows the improvement in OEE and reduction in down time by implementation of basic principles of TPM. By analyzing the results, conclusions have been drawn and suggestions for further scope have been provided.