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Implementation of Total Productive Maintenance (TPM) to Improve Overall Equipment Effectiveness (OEE) - Case Study

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Intelligent Systems in Production Engineering and Maintenance III (ISPEM 2023)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

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Abstract

Modern companies are operating under economic conditions resulting from the global crisis. This situation forces organizations to constantly look for solutions to increase the efficiency, productivity, and flexibility of processes, including manufacturing. In practice, this means implementing solutions based on the Lean Management philosophy. These solutions aim to eliminate waste in various spheres and areas of business operations. Concerning manufacturing companies and manufacturing processes, wastage includes overproduction, underproduction, downtime, machine breakdowns, maintaining unnecessary inventory, or prolonged search for tools and materials. This article aims to analyze the causes of low OEE indicator and its improvement based on a new model of maintenance and overhaul of the machinery fleet in the example of an automotive manufacturing company. Based on the analysis, observations, and interviews with employees documented: the calculation of production capacity calculation of the number of correctly produced strips in the period before the introduction of the new plan for maintenance and overhaul of the equipment used on the KP production line, calculation of the OEE indicator for the entire production process on the KP line, creation of a list of failures occurring at the building and vulcanizing stations, as stations constituting a bottleneck in the production process, calculation of the OEE indicator for machines at the building and vulcanizing stations, categorization of machines and creation of a new model for maintenance and overhaul of the equipment used on the KP production line.

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Authors and Affiliations

  1. Faculty of Technical and Economic Sciences, Witelon Collegium State University, Sejmowa 5A, 59-220, Legnica, Poland

    Damian Jurewicz, Magdalena Dąbrowska, Daniel Medyński, Piotr Motyka & Krzysztof Kolbusz

  2. Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, Wybrzeże Wyspiańskiego 27, 50-370, Wroclaw, Poland

    Anna Burduk

  3. University of Minho, MEtRICs Research Centre, 4804–533, Guimarães, Portugal

    José Machado

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  1. Damian Jurewicz
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  2. Magdalena Dąbrowska
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  3. Anna Burduk
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  4. Daniel Medyński
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  5. José Machado
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  6. Piotr Motyka
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  7. Krzysztof Kolbusz
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Correspondence to Magdalena Dąbrowska .

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Editors and Affiliations

  1. Wrocław University of Science and Technology, Wrocław, Poland

    Anna Burduk

  2. Liverpool John Moores University, Liverpool, UK

    Andre D. L. Batako

  3. University of Minho, Guimarães, Portugal

    José Machado

  4. Silesian University of Technology, Gliwice, Poland

    Ryszrad Wyczółkowski

  5. Poznań University of Technology, Poznan, Poland

    Ewa Dostatni

  6. Kazimierz Wielki University in Bydgoszcz, Bydgoszcz, Poland

    Izabela Rojek

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Jurewicz, D. et al. (2024). Implementation of Total Productive Maintenance (TPM) to Improve Overall Equipment Effectiveness (OEE) - Case Study. In: Burduk, A., Batako, A.D.L., Machado, J., Wyczółkowski, R., Dostatni, E., Rojek, I. (eds) Intelligent Systems in Production Engineering and Maintenance III. ISPEM 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-44282-7_42

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