Implementation of 5S and Kobetsu Kaizen (TPM Pillar) in a Manufacturing Organization (original) (raw)
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5S activities and its application at a sample company
Total Productive Maintenance (TPM) targets enabling the machine operators to undertake the maintenance activities and therefore to increase the efficiency of the equipments. It struggles with six great losses decreasing the efficiency of the equipment. 5S, which is the pre-step of TPM, is a systematic approach providing the contribution of all personnel in the cleaning regime of the company. The clean and steady environment targeted by 5S has positive impacts on the work safety, quality, efficiency and morale. In this study, 5S system, used for ensuring order and discipline in the companies and ensuring the supervision of both simple and even the smallest details, has been reviewed in full details and they have been taken under the content of the research through selecting the assembly department as pilot department for 5S activities applied at a yacht manufacturing company. It has been targeted to set this as a guide for the directors of the company and the researches working in this field by assessing the results of this study.
SINERGI
In this global era where the level of competition is higher, in addition to the influence of the suitable marketing strategy is also required strategy from the side of production/productivity. PT. XYZ is a company engaged in the manufacturing of snacks especially biscuits. The problem that often occurs in this company is the number of biscuits that are not in accordance with the standard and the production does not reach the target set because the machine suddenly breaks down frequently. To overcome the problems PT. XYZ then choose to implement the Total Productive Maintenance (TPM) strategy. This study aims to evaluate the implementation of 8 TPM Pillars and measure the effects on manufacturing performance in the form of Overall Equipment Effectiveness (OEE) and Waste. This study uses questionnaire-based survey method. The number of samples distributed is 40 units. Which returned and filled 33 questionnaires and which is worth to be processed as many as 30 samples. Then tested the ...
Quality Innovation Prosperity, 2019
Purpose: IATF 16949:2016 standard requirements do not represent a totally new approach of quality improvement within the automotive industry. The change of the last, from 2009 year ISO/TS), the quality management standard is only an expected consequence of changes, which, in managerial systems, was brought by ISO Organization in 2012 (Annex SL). Implementation of the Total Productive Maintenance (TPM) requires several important steps. The article describes framework of TPM implementation on a basis of PDCA (P-plan; D-do; C-check; A-Act) cycle and evaluates influence of Occupational health and safety pillar (OHS) on the "stability" of TPM house. Methodology/Approach: Individual steps of TPM implementation are analysed and added with suitable tools for making the effective integration of TPM and IATF (which is expansion of ISO 9001:2015). Findings: Implementation of autonomous maintenance and other TPM pillars requires support from management. Although the 5S tool is understood as a basic TPM tool, knowledge from its implementation suggest the fact that 5S is also a significant tool of management integration within organisation. Research Limitation/Implication: Research presented in this article is influenced of the maturity of organisation as well as its size and types of its activities. Originality/Value of paper: Method of TPM implementation analysis in the conditions of integrated approach with an emphasis on 5S and its relation to OHS management is original approach.
European Journal of Applied Sciences, 2023
The purpose of this research is to design fundamental base for continuous improvement in maintenance that serves improving machine’s reliability and raises the productivity, to fix strong products in the market with perfect quality and competitive price. Zero breakdowns, zero defects and zero accidents are the target to possibly improve productivity, save costs by reducing wastes and equipment longevity. Making the workplace is healthy organizational environment and better performance, increases the work team spirit by appropriate follow instruction of the implementation and mutual respect and understanding between managers and employees. Design / Methodology / Approach: The data were collected using questionnaire, company’s documentation, interview and observations for 6 months at the lines of the company. The assessment is based on the overall equipment effectiveness (OEE), productivity and profitability approach. Cause-Effect diagram and Pareto chart techniques were used for identifying the problems in the production lines. The 8 pillars and others worksheets of TPM are used for 6 months period. Finally, OEE and its indexes were used as measuring of success the TPM implementation. Findings - The suggested scheme was effective in increasing the overall equipment effectiveness from 48 % to 85 % over a 6 months period. The parameters of OEE were a direct orientation of improvements in equipment availability, performance and product quality by highly recommendation on the pillars of TPM. This work may have exploits on the consistency of TPM nature to improve maintenance scheme for a generic system. The tools and worksheets presented can be helpful to managers and operators. Originality / value: Total productive maintenance (TPM) is one of the numerous diagnostic/prognostic maintenance strategies have been employed in this study. This research has implemented an integrated OEE and its parameters/managers and normal labors in order to clarify the cause / effect to make action for the critical/chronic lines to remedy the low production. This is the first time that the TPM in this company has been placed and its impact is gained after that specific and short period.
International Journal of Engineering and Management Research, 2020
Total Productive Maintenance (TPM) focuses on maximizing equipment performance, establishing a productive maintenance system that optimizes its life cycle, contributing for the continuous improvement and availability, avoiding early equipment wear, being necessary that the maintenance works on preventing with managerial focus. In this study, the impact of each implemented TPM pillar in the Overall Equipment Effectiveness (OEE) metric was analyzed, evaluating the performance resulting from each implemented pillar. The approach of the research is predicated on the Survey method, based on the intentional sample of the industrial companies in Brazil, which implemented the method. The results evidenced that the Focused Improvement and Planned Maintenance pillars were implemented in most of the respondent companies, being part of different segments, such as metallurgical, food, textile, auto-parts, household appliances, school material, automobile and chemical products. The OEE metric showed the TPM evolution comparing the result at the beginning of the implemented activities and at the end. Other important observation was in the implementation of the pillars, when compared with the suggested literature, a change of priority and sequence occurred. The Autonomous Maintenance pillar was suggested as the second pillar to be implemented. It is implemented only after the Training and Education pillar, which is the fourth suggested pillar. The other pillars were implemented in the original sequence indicated by literature.
2015
Abstract: Aim: Total Productive Management (TPM) is a strategic change management approach that has considerable impact on the internal efficiency of manufacturing organization, both in the developed countries and developing countries. It is an innovative maintenance program with a concept for maintaining plant and equipment by the involvement of all personnel based in an organization for continuous improvement of performance. The purpose of the research was to evaluate the impact TPM pillars have on equipment availability focusing on the planned maintenance pillar. The research objectives were to; determine how the planned maintenance pillar was used at the company under study and the extent to which it was applied; to determine the impact that TPM had on the company’s performance and finally to determine if the TPM pillars had helped in obtaining the overall expected results that rise from an effectively implemented TPM. Methodology: A literature survey was undertaken into the ele...
2020 Advances in Science and Engineering Technology International Conferences (ASET), 2020
Maintenance has traditionally been viewed as a support and 'nonvalue adding' function of a business. Managing equipment performance has not been a top priority until recent years in manufacturing industry. The inadequacies of maintenance practices in the past, have adversely affected organisational competitiveness. The manufacturing sector globally has witnessed drastic changes in the later part of 20th century. In the highly challenging environment, the quest for reliable manufacturing equipment has necessitated manufacturing organisations to accept equipment maintenance as an indispensable function for ensuring sustained profitability of enterprises. As organisations across the globe have faced stiff cut-throat competition in the last three decades, Indian industry too could not escape the brunt of globalisation. The purpose of this study is to highlight achievements of an Indian manufacturing enterprise through strategic Total Productive Maintenance (TPM) initiatives. TPM implantation initiatives in an Indian manufacturing organisation have been investigated to ascertain benefits accrued as a result of successful TPM implementation.
Challenges in implementing Total Productive Maintenance in Indian Manufacturing Industries -A Review
IRJET, 2022
In today's Indian manufacturing industries, practicing of Total Productive Maintenance (TPM) has been widely accepted and implemented, yet it is still possible to find industries facing maintenance challenges. The main objective of this review paper is to identify the hurdles of TPM implementation and its benefits after the effective implementation of TPM in the Indian manufacturing industries. Total productive maintenance is practical approach that targets maximizing the effective use of facilities that are available within an organization. Total productive maintenance builds a well-defined system of productive maintenance, encompassing the entire life cycle of equipment, covering all department in industry, involving participation of all associates from high level to bottom level and promotes small group autonomous activities. During the progressive growth period the companies are exhibiting the core technical progress in plant automation and centralization, which necessitates remarkable amount of human work to maintain the automation systems. The strategy of maintaining the equipments at their highest performing level is most important for the profound results in manufacturing. As the competitive edge in the world market continues to increase the pace of its progress, our review paper work intends to help companies to look for TPM implementation strategies and look for the possible barriers which other organizations faced during TPM implementation phase, to save on costs, develop employees to face future challenges and bring about a new working culture at their work place.
Total Productive Maintenance: A Case Study in Manufacturing Industry
The purpose of this paper is to evaluate the contributions of total productive maintenance (TPM) initiatives towards improving manufacturing performance in Ethiopian malt manufacturing industry. The correlations between various TPM implementation dimensions and manufacturing performance improvements have been evaluated and validated by employing overall equipment effectiveness (OEE) in boiler plant. The research focuses upon the significant contributions of TPM implementation success factors like top management leadership and involvement, traditional maintenance practices and holistic TPM implementation initiatives, towards affecting improvements in manufacturing performance in the Ethiopian industry. The study establishes that focused TPM implementation over a reasonable time period can strategically contribute towards realization of significant manufacturing performance enhancements. The study highlights the strong potential of TPM implementation initiatives in affecting organizational performance improvements. The achievements of Ethiopian manufacturing organizations through proactive TPM initiatives have been evaluated and critical TPM success factors identified for enhancing the effectiveness of TPM implementation programs in the Ethiopian context.
The competition in business environment becomes more strictly, manufacturers must introduce lots of new products on the high quality level with suitable price. Thus, new technologies have been applied, manufacturing systems become more complex. Therefore, a new strategy for maintenance such as Total productive maintenance (TPM) becomes really necessary. Many organizations have implemented TPM to increase the effectiveness of manufacturing system. However, implementation of TPM still meets a lot of drawbacks. This paper, will focuses on the factors can help implementing the TPM successfully in manufacturing organizations. This study is an attempt to look at the successful factors of TPM implementation at NS BlueScope Vietnam, a steel manufacturer