Implementation of Total Productive Maintenance to Enhance the Overall Equipment Effectiveness in Medium Scale Industries

In current globe state, manufacturing companies are in need of sustaining their production level to meet the customer demand. Whenever capacity problem arises, immediately they look for increasing overtime, number of shifts and purchase new machines and equipments. As an alternative, they should focus on the better utilization of resources and increasing performance of the existing machines which leads to an improvement in the equipment performance, reduction in bottlenecks, decrease overall downtime, improve operator performance and minimize setup time and other major forms of losses, thus enabling in decision on the investment of buying new machines. In this research, an attempt was made to implement total productive maintenance to achieve overall equipment effectiveness (OEE) close to world class standards. Result analysis shows that, downtime losses are not the only influencing parameter, but idle time of a machine is another factor that adds to the variation in OEE. It is evident that the percentage OEE can be improved substantially by implementing total productive maintenance lean tools such as Jishu Hozen, Kaizen etc in a manufacturing company. While calculating OEE, the factors influencing it are identified and performance improvement measures are undertaken. From the observed results, it was found that, the percentage OEE can be improved from 55.45% to 68.04% by implementing this technique in medium scale industries.