Session: 14-03-01: Reliability and Safety in Industrial Automation Systems

Paper Number: 66623

Start Time: Monday, 06:10 PM

66623 - Improving Overall Equipment Effectiveness by Enabling Autonomous Maintenance Pillar for Integrated Work Systems 

Growth toward a global economy and manufacturing world has expanded based on competition and meeting the best share market [1]. Organizations adopt and practice various approaches to increase their overall manufacturing performance [2–4]. To measure the overall manufacturing performance, it is vital to measure the performance of individual equipment or small sub-section within the production department as these are the heart beat for any industry. Interestingly, overall equipment effectiveness (OEE) is the most effective and popular concepts used to measure the performance of individual equipment that identifies the percentage of total planned production time that is truly productive [5].

Integrated Work System (IWS) and Overall Equipment Effectiveness (OEE) are the two most popular and fundamental concepts used in operations and production firms to evaluate performance in the manufacturing process by identifying and eliminating the causes of production losses. In the area of high performability and the competitive nature of the business market, companies must increase their efficiency in the manufacturing process. The concept of OEE is becoming increasingly popular and has been widely used as a quantitative tool for measuring the performance of total productive maintenance (TPM). While IWS is an approach that integrates equipment, processes, and involvement of people into a unified approach to reduce costs, improve quality, and increase productivity. Principally, IWS main goal includes maximizing OEE to eliminate equipment failure and defects, minimizing downtime and maximizing productivity with less time, effort and waste. The purpose of this work is to compare the performance of the OEE with the implementation of the IWS pillar i.e. autonomous maintenance (AM). The rollout of the AM pillar was carried out on the two identical packaging machines (HLP1) with a speed of 120 packets per minute. The data which is shown in this paper is for both machines during the operational hours.

This research particularly looked at rolling out the AM pillar of IWS to improve the OEE of the cigarette factory in the Pacific. Out of twelve pillars, only AM pillar was accomplished on the two identical packaging machines (HLP1) with a speed of 120 packets per minute. The operating time for each machine was 570 minutes from Monday to Thursday and 540 minutes on Friday.

Along with production, the AM was rolled out to see the performance of the machine in terms of quality production for five months (January to May). The aim for it was to restore and prevent accelerated deterioration thus impact OEE with a positive note. It is a skill development program which improves the process failure, stabilize equipment conditions and develop training materials on how to run, operate & maintain equipment rather than production teams carrying out maintenance tasks.

Finally, the analysis showed positive results for both machines within a five-month period with an increase of 27% and 15% in OEE respectively. TPM has greatly monitored the MTBF, downtime and waste management which maximized OEE in general.

Reference

[1]    P. Maskell and A. Malmberg, “Localized learning and industrial competitiveness," Cambridge J Economics, vol. 23, no. 2, pp. 167-185, 1999.

[2]    S. G. Azevedo, H. Carvalho and V. C. Machado, “The influence of green practices on supply chain performance: a case study approach,” Transport Res Part E: Logis Transport Rev, vol. 47, no. 6, pp. 850-871, 2011.

[3]    A.N. Raymond, R.H. John, G. Barry and M.W. Patrick, Human resource management: Gaining a competitive advantage, 4th ed., New York, NY: McGraw-Hill Education, USA, 2002, pp. 352-370.

[4]    J. Combs, Y. Liu, A. Hall and D. Ketchen, “How much do high‐performance work practices matter? A meta‐analysis of their effects on organizational performance,” Personnel Psych, vol. 59, pp. 501-528, 2006.

[5]    P. Muchiri and L. Pintelon, “Performance measurement using overall equipment effectiveness (OEE): literature review and practical application discussion,” Int J Product Res, vol. 46, pp. 3517-3535, 2008.

Presenting Author: Sumesh Narayan University of the South Pacific

Authors:

Aneesh A. Chand University of the South Pacific
Kushal A. Prasad University of the South Pacific
Krishneel R. Sharma University of the South Pacific
Sumesh Narayan University of the South Pacific
Kabir A. Mamun University of the South Pacific
F. R. Islam University of Sunshine Coast
Nallapaneni Manoj Kumar City University of Hong Kong
Shauhrat S. Chopra City University of Hong Kong