Analysis of Causes of Low OEE and Improvement by Implementation of TPM and 5S Techniques in Manufacturing Industry

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1 Analysis of Causes of Low OEE and Improvement by Implementation of TPM and 5S Techniques in Manufacturing Industry MEGHRAJ 1*, Dr.SridharK 2 1 M.Tech.Scholar, Dept.of Mechanical Engg. CSIT, Durg. meghraj.chandra@gmail.com 2 Professor in Mechanical Engg. CSIT, Durg. anusrinaga@gmail.com Abstract The purpose of this paper is to evaluate the contribution of TPM at a stretch in industry to sort out the root causes for Low OEE. TPM is an evolutionary with the changing time which keeps plant and equipment in good condition to increase the productivity. Overall equipment effectiveness (OEE) plays an important role in the industry which shows the total efficiency of plant working. Due to sudden failure and breakdown occurs in the and increases the cost of maintenance, which results in low availability, poor performance and low quality, and ultimately the OEE become low. The main objective of this study is to improve OEE with the help of TPM and 5S using a systematic approach, the 4 were analyze which help in finding the root causes of s. The OEE was found to less than world class OEE (85%). Further, a model is constructed to reduce the losses in the manufacturing industry which improves the effectiveness of the plant. Key words: TPM (Total productive maintenance), OEE (Overall Equipment Effectiveness), Cause and effect Diagram, Availability, performance, Quality. 1. Introduction Total Productive Maintenance (TPM) is a maintenance process originated in Japan in1971as a method to improve the availability of through better utilization of maintenance and production techniques. TPM is developed for improving the productivity by reducing breakdown and eliminating unnecessary operation. TPM is an extension of TQM (Total Quality Management) means that TPM is not only based on quality but also with the availability and performance rate. The objective of TPM is to maintain plant and equipment in good condition without any major changes in the process. To achieve this objective TPM implementation plan and 5S technique is required. In most of the country TPM becomes a power tool to reduce the uncertainty in the work. In today s fast-changing marketplace it is very necessary to improve the productivity otherwise survival of an organization become difficult. Thus it is very essential for the organization to improve faster than their competitors. Total Productive Maintenance was introduced in early 1950 s by Japanese. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960.In current status TPM has gain the popularity in the manufacturing industry in the last few years. The method aims at eliminating frequent failures and breakdowns, defects and improves the working condition [1]. The TPM based on the concept to achieve 4 zeros:- 1. Zero Defects 2.Zero Breakdowns. 3. Zero Wastes. 4. Zero Accident It is impossible to achieve all the four zeros permanently, but possible to get closer to these Zeros which beneficial for the industries to reduce extra cost occur due these four factors.

2 Overall it focus on to remove all non-value added operation, while it is not possible to achieve all 4 zeros permanently but by the implementation of TPM it is possible to come closure to 4 zeros. The method makes it possible to improve organization, increase efficiency and effectiveness and minimize the accident rate [2]. By the continuous practice of TPM and 5S in the industry may reduce failure and breakdown which tends to increase the productivity. 2. Literature Review The contribution of total productive maintenance (TPM) helps to improves manufacturing performance of the industry. The correlations between various TPM implementation plan and manufacturing performance improvements has evaluated and validated by employing overall equipment effectiveness (OEE). Cost of rework and repairs reduced due to very limited products rejected because of equipment failure. Thus, the TPM implementation improves the overall effectiveness of equipment significantly [3]. The author (Hemant Singh Rajput and Pratesh Jayaswal [4]) have selected s to analyze the different aspects of s. Data for past have been analyzed and results achieved is increased 20% in OEE much beneficial in point of view to improvement in overall equipment effectiveness (OEE), reduce the waste and reduction in no. of accidents on shop floor of the plant and the author (Mohammedasif Mulla and Ramesh C.G [5]) identified the root causes for problems occurring on Horizontal Machining Centre (HMC) s. The fish-bone diagram helps to sort out the causes for bottleneck problem in. The TPM and 5S techniques were used to take the corrective action and to improve the OEE of. HMC increased in OEE from 40.08% to 44.41%. To reduce the unwanted breakdown stoppage, unnecessary operation, accident and losses in the most of the Indian industries maintenance, TPM is considered as the tool help to minimize the problem. By the implementation of TPM can increase the equipment effectiveness and productivity [6]. The author (Rajesh Attri, Sandeep Grover, Nikhil Dev and Deepak Kumar [7]) prepared certain questionnaires based on survey an interpretive structural modelling (ISM) approach has utilized in analyzing their mutual interaction. An ISM model has prepared to identify some key factors and the implementation of TPM and the author (Binoy Boban and Jenson Joseph E [8]) recognize the objective of the work is to increase the overall equipment effectiveness (OEE) by the implementation of total productive maintenance (TPM) plan. The company has to suffer due to lower availability of s the performance rate also decreases as a result of breakdowns which may leads to possess extra cost during the production. After a small implementation of TPM in company, it is found that the Overall equipment effectiveness is increased by 4%. The author (Papari Das and Thuleswar Nath [9]) identified the Root causes in the tube section manufacturing company and necessary recommendations made to reduce the most significant equipment breakdowns. TPM is a concept to maintain and equipment in good condition so that it performance and quality rate increases. The six big losses were considered for the purpose of analysis and the main focus is to sort out to reduce the losses and finally which improve the OEE thus it removes unwanted operation and increase the productivity [10]. The author (Moyeen Kadri, Amit Kumar and Arun Kumar Bhuneriya [11]) implemented Total productive maintenance in Indian textile industries to improve OEE. The implementation of TPM helps to improve productivity, empowering the employee to make decision and the value adding process which result to increase the OEE. Total Productive Maintenance (TPM) approach reduce the cycle time of assembly by implementation of 5S methodology and TPM pillars like 5S, Kobestsu Kaizen, JishuHozen, office TPM, Planned Maintenance, Safety Healthy and Environment and Education and Training. Pillars will be implemented in such a way that it reduce the cycle time reduction and improve upon the process of the assembly procedure [12]. The entire concept based on the TPM is just to reduce the cost of the maintenance which helps to increase the productivity of the industry by the implementation of TPM technique. The main function of the TPM is to change or improve the different aspect of the method involve in the production.

3 3. Methodology The OEE data of the 4 s have been collected for a period of ten months in 2015 from MARS1 Bhilai steel plants Chhattisgarh. Among the 4 s, Vertical boring, Horizontal boring, horizontal lathe, Gear cutting having the lowest OEE have been selected for the analysis purpose of equipment breakdowns. The figure of all 4 s has shown below. This paper presents a systematic way to investigate the root causes for low OEE and arrive at the solution of bottleneck problems in the industry. The methodology employed to identifies the existing operations in the facilities with the help of detailed study and questionnaires. The average values of Overall Equipment efficiency and Total Productivity of the industry is calculated and compared against world class standards. Further root cause barriers are pointed out to reduce unproductive time and to increase the overall equipment effectiveness and efficiency of the existing system. Table 1 show that the allowance given to the employee during the working hours and Table 2 represent the data collected during the analysis of which gives the information regarding the having the low OEE. Figure 1: Vertical boring Figure 2: Horizontal boring Figure 3: Gear cutting Figure 4: Horizontal Lathe

4 Table 1: The following allowances are considered by the industry. Number of Shifts 2 Working time per shift Break time for food Break time for Tea Meeting time 8 hours 30 minutes for each shift 15 minutes(twice in a shift) 15 minutes for each shift Machines/ Factors (hours) Vertical boring Table 2: The following are the data observed. Horizontal boring Horizontal lathe Gear cutting schedule run time Actual run time Targeted no. of items No. of items yield Defected items Calculation Of Overall Equipment Effectiveness The method used is to analyze the current Overall Equipment Effectiveness OEE of the and compare it with world class OEE in manufacturing. And then TPM and 5S technique are implemented to improve the OEE. The first step is to collect the data and analyze schedule run time, actual run time, targeted no. of items, no. of items yield, defected items and calculating the OEE in terms of Availability, performance, and quality of the components. Table 3 shows the availability, performance, Quality and OEE of the s and figure 4.1 shows the comparison of different factors with the help of graph. Overall Equipment Effectiveness is calculated by: OEE=Availability Performance efficiency Rate of quality 1. Availability: 2. Performance Rate:

5 3. Quality Rate: Table 3: The result of OEE obtained from s and world class OEE Machine /Factors Availability Performance Quality OEE Vertical boring Horizontal boring Horizontal Lathe Gear cutting World class OEE Availability Performance Quality OEE 0 Vertical boring Horizontal boring Horizontal Lathe Gear cutting World class OEE Figure 5: comparison of obtained OEE with World class OEE The above histogram figure 5 shows that the OEE of all the 4 s is lower than the world class OEE (85%).

6 5. Corrective Approach 5.1. TPM implementation plan 1. Autonomous Maintenance-This pillar is focused towards developing operators to be able to take care of small maintenance task, therefore it become important to understand the problem which is carried out by spending more and more time in maintenance to add more activity to reduce stoppage. 2. Focused maintenance-aim to continuous inspection which leads to result zero losses with respect to unplanned down, measurement and adjustments, defects and avoided unnecessary down times. 3. Planned maintenance-planning of the maintenance is beneficial as it make it trouble free s and equipments, producing defect free products in the industry and thus raise productivity. It divides maintenance into 4 parts or groups as a. Preventive Maintenance b. Breakdown Maintenance c. Corrective Maintenance d. Maintenance Prevention. 4. Quality Maintenance-Quality maintenance activities are perform in such a way that the number of rejected or defective product get minimize for which require less investment in handling those defective items during the production period. 5. Education and Training-It is one of the important pillar aimed to develop multi skilled to the employees, so that the morale of the employees get high and whose efficiency to work and performance will increase. 6. Safety, Health &Environment- Focus on ensuring safety, occupational health and clean and safe environment. All these condition provide to employees so that he perform his job in well manner. 7. Office TPM- To improve rate of production, effectiveness and efficiency of administrative functions in the industry by eliminating the losses and barriers. 8. Development management-planning to execute project, analyzing the factors influencing project decision, design new products with customer focus, and reduce lead time from design to production to market. Figure 6: Pillars of TPM [13]

7 5.2. 5S Technique 5S is the base of the TPM which is beneficial to uncover the various problems. It is a systematic process requires the commitment of employees for the implementation and housekeeping. On the basis of 5S it become easy to observe or monitor the process and evaluates the problem. After the implement of 5S the process gets improved. 1. Sort/ Clear (Seiri) Sort out the items from the work place and eliminate them according to the priority items usage. No longer needed items discard which make the work place free to use without any interruption. 2. Set in order/configuration (Seiton) - By placing the items in a proper order it become easy to perform a work more frequently. It should be arrange in correct position, correct place, and correct material with a proper holding system which make easy to identify needed item. 3. Shine/Clean and check (Seisio) - Clean and check the equipment and workplace to make it free from dirt, dust, oil, debris etc. This technique helps for the reduction of the unwanted causes. 4. Standardize/Conformity (Seiketsu)- It is one of the important aspects to maintain standard of an item by keeping the workplace in organized manner which helps to maintain the quality also. 5. Sustain/custom and practice (Shitsuke) - Maintaining the standards and procedures and in continuously improving the 5S state of the workplace. These make item more sustainable in the market with the help of 5S technique. 6. Analysis Some of the root cause of the s were sorted out by the analysis of during the working shift of the, which majorly effecting the machining work of the and cause unproductive time which leads to delay in finishing the machining work of the job and ultimately it become burden to entire department of shop. MEASUREMENT MAN MATERIAL Measurement error using old method Old Equipment Heavy job Faulty component Low accuracy No planning for tools Component failure Wrong Adjustment Lack of training Handling problem Corrosion How to identify error LOW OEE Unavailability of handling system Impatience Improper maintenance No oil change Poor driving habit No awareness wrong oil Job setup problem Always late Old Lubrication problem Lack of TPM method Tool changing problem don t know right oiling HANDLING METHOD MACHINE Figure 7: Cause and effect Diagram- Analysis for Low OEE

8 7. Proposed Model The proposed model is useful for the implementation of TPM in the industry in which they have to follows certain result and analysis. Ultimately increases the result of OEE of the shop of manufacturing industry. MARS-1 (MACHINE ASSEMBLY REEENGINEERING SHOP-1) MACHINE PREPARATION OF PROGRAM FOR OPERATION DETAIL DESCRITION OF PLANNING, SCHEDULING & ALONG MAINTENANCE EXECUTION ASSESING THE EXISTING MAINTENANCE SYSTEM WITH MEASURING TOOL OEE IMPLEMENTATION OF TPM (TPM PILLARS) MAKE IMPROVEMENT PLAN MONITOR & ANALYSIS THE RESULT OF OEE INCREASE IN THE RESULT OF OEE NO SORT OUT THE BARRIERS YES ESTABLISHING TPM PROMOTION ORGANIZATIONAL MODEL Figure 8: Proposed Model of TPM Implementation for the enhancement of the Machine Shop of manufacturing industry.

9 8. Conclusion TPM and 5S is one of the important techniques having multi feature to reduce the losses and provide benefit with proper implementation to enhance OEE. The root causes of the s were analyzed and highlight such problems, then it may lead to corrective action for problem such as unplanned stoppage, breakdowns and rework. In this analysis we observed that all 4 s have low OEE than the world class OEE (85%) which requires improving OEE. Therefore by the continuous implementation of TPM and 5S with the help of propose model in the manufacturing industry it become easy to sort out the root cause problem and reduce the losses and accelerate the rate of performance, availability, quality and finally lead to increase the OEE and hence ultimately increase the productivity and profitability of the industry. It can be concluded that the industry may use the model constructed by applying TPM and 5S technique in order to accelerate OEE and to improve the current maintenance system. References [1] Osama Taisir R Almeanazel, Total productive Maintenance, Review and Overall equipment effectiveness, Jordan journal of Mechanical and Industrial Engineering, Vol.4, pp , 2010, ISSN: [2] B. Gajdzik, Introduction of Total productive Maintenance in steelworks plants, Pregledni rad METABK, Vol.48 (2), pp , 2009, ISSN: [3] Melesse Workneh Wakjira, and Ajit Pal Singh, Total Productive Maintenance: A Case Study in Manufacturing Industry, Global Journal of researches in engineering Industrial engineering Volume 12 Issue 1 Version 1.0 February [4] Hemant Singh Rajput and Pratesh Jayaswal, A Total Productive Maintenance (TPM) Approach to Improve Overall Equipment Efficiency, International Journal of Modern Engineering Research (IJMER), Vol.2, Issue.6, Nov-Dec, 2012 pp ISSN: [5] Mohammedasif Mulla and Ramesh C.G, Enhancing Overall Equipment Effectiveness of HMC Machines through TPM and 5S Techniques in a Manufacturing Company, International Journal on Mechanical Engineering and Robotics (IJMER), Volume-2, Issue-2, 2014, ISSN (Print): [6] Sudhansu Pandey, Sharada Pratap Shrivas and Rachit Kumar Shandollar, TPM Implementation on Case Study of Coal Washery, Journal of Harmonized Researches in Engineering, 2(1), 2014, , ISSN: [7] Rajesh Attri, Sandeep Grover, Nikhil Dev and Deepak Kumar, An ISM approach for modelling the enablers in the implementation of Total Productive Maintenance (TPM), Int J Syst Assur Eng Management, Oct-Dec, 2013, 4(4): [8] Binoy Boban and Jenson Joseph E, Enhancing Overall Equipment Effectiveness for a Manufacturing Firm through Total Productive Maintenance, Volume 3, Issue 8, August 2013, ISSN: [9] Papari Das and Thuleswar Nath, Root Cause Analysis of the Major Equipment Breakdown Problems of the Tube Section of a FMCG Company as an Approach to Improve OEE, International Journal of Engineering Trends and Technology (IJETT) Volume 27 Number 4 - September 2015, ISSN: [10] B.C. Ashok and Dr. T.R. Srinivas, Overall Equipment effectiveness of Critical Machines in Manufacturing Industries A Practical Analysis, International Journal of Mechanical Engineering and Technology (IJMET), Volume 5, Issue 9, September, 2014, pp , ISSN: [11] Moyeen Kadri, Amit Kumar and Arun Kumar Bhuneriya, Performance improvement through TPM implementation in Textile Industry, Asian Journal of Convergence in Technology Volume1, Issue 6, 2015, ISSN: [12] Parth N Chandegra and Vivek A. Deshpande, Cycle Time Reduction of PCF Gearbox using Total Productive Maintenance (TPM) Approach, International Journal of Advance Industrial Engineering, Vol.3, No.2 June 2015, ISSN: [13] Thomas R Pormoski, Total Productive Maintenance: Concepts and Literature Review, the Union Institute and University, April 30, 2004.