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CNC Machine Analysis
CNC Machine Analysis
Abstract
In the generation of agile manufacturing, the machines and its functions are also becoming complex. OEE of a
machine plays an important role in present scenario where delivery and quality are of prime importance to customer. The
paper reports a case study for improving OEE with help of TPM and 5S techniques using a systematic approach.
The present aimed at minimizing the breakdowns, increasing performance and quality rate of machine thus
improving the effectiveness. Initially the machine history was analysed which helped in finding the bottleneck machine.
The OEE was found to be 43% in the identified bottleneck machine. Further, a TPM team was formed to devise a
systematic approach to improve the effectiveness. The project has been addressed in three aspects; namely Availability,
Performance and Quality which quantify OEE of a machine. The TPM techniques such as Preventive Maintenance,
Cleaning with Meaning, Pokayoke & Kaizen were effectively applied on the machine.
The result obtained from the TPM approach showed that the OEE was improved from 43 % to 72 % which indicated
the desirable level in al manufacturing industry. To sum up, total saving per annum due to increased effectiveness was
around Rs 4,53,000/-.
Key Words: Overall Equipment Effectiveness (OEE), TPM, SOP, Kaizen, Pokayoke and 5S.
Abbreviations
OEE
SMED
SOP
TPM
TQM
1. INTRODUCTION
In this age of agile manufacturing the global
competition characterized by both technology push and
market pull has forced the companies to achieve worldclass performance through continuous improvement in
their products and processes. Today, various innovative
techniques and management practices such as total
preventive maintenance (TPM); total quality
management (TQM); business process reengineering
(BPR); enterprise resource planning (ERP) and just in
time (JIT), etc. are becoming popular among the
business houses. [1]
Fig. 2 OEE Methodology
This metric has become widely accepted as a
quantitative tool essential for measurement of
productivity in manufacturing operations. The OEE
measure is central to the formulation and execution of a
TPM improvement strategy. TPM has the standards of
90 per cent availability, 95 per cent performance
efficiency and 99 per cent rate of quality. An overall 85
per cent benchmark OEE is considered as world-class
performance.This case study aims in bringing the OEE
near to 75% and gradually move up towards world class
manufacturing. [2]
TPM employs OEE as a quantitative parameter for
measuring the performance of a production system.
OEE is the core metric for measuring the success of
TPM implementation program (Jeong and Phillips,
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2. PROBLEM DEFINITION
Historical organizational data showed the Overall
Equipment Effectiveness (OEE) value was very low
compared to the general manufacturing scenario. Due to
which the machines were not utilized effectively and
hence production rate and volume was affected.
Figure 4 shows the OEE value of 2 machines LT-2
& Max 65 respectively. These machines had lower OEE
values compared to other machines. These machines
were a part of cell in line production. They were
hindering line efficiency.
2.2 Methodology
Target
Followed
for Achieving
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CNC turning
center (LT -16)
Bottleneck
Machine in
the cell
Parts waiting
to be processed
and piled up
No load due to
breakdown &
slow cycle time
.
Deburring
ce
n
te
r(
S
-3
3
)
C
N
C
m
a
ch
in
in
g
Conventional
milling
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.
Fig. 12 Abnormalities found in the machine
After the TPM team had taken up the initiative for
cleaning of the machine, the team had observed around
50 problems which were tagged and then rectified.
Performance approach: To improve performance,
machine cycle time was focused upon which was the
second cause for inefficiency. Kaizens were adopted on
the machine. To reduce the cycle time two points were
considered,
1) To combine the tools if it is feasible
2) To see the operations and to see whether it could
be improvised
From the options it was found that both the
possibilities could been implemented to improve the
current process. The modification done is explained in
the following section.
TPM team members conducted a brainstorming
session and came with some ideas and created a Cause
& Effect diagram shown in figure 14 for the high cycle
times.
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120
50
100
40
80
30
60
20
40
10
20
y
c
n
e
u
q
e
r
F
e
v
it
a
l
u
m
m
o
C
0
Missing Availability Broken
Unwanted
Not
Working
Dirt
loose
wear
dislocation
insufficient
Total PPM
space
PPM
16
53
CC
26.04
39.25
50.57
60.00
65.66
73.21
78.87
84.53
90.19
95.85
100.00
PPM
Defects
CC
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Before
After
31
Total Time
in (Min)
2264
1599
Cycle time
in (Min)
1600
1267
Before
68%
67%
95%
43%
After
90%
85%
95%
72%
REFERENCES
[1] C.J. Bamber, P.Castka, J.M.Sharp, & Y.Motara,
2003 Cross Functional team Working for Overall
Equipment Effectiveness, Journal of Quality in
Maintenance engineering, Vol 9 No.3, pp. 223-238
[2] Albert H.C.Tsang & P.K.Chan, 2000 TPM
implementation in China: a case study,
International Journal of Quality & Reliability
Management, Vol 17 No.2, pp.144-157
[3] P.Sharma, Vishwas Bhave, Dr. H.B. Khurasia, &
B.Shikari
Enhancing
overall
equipment
effectiveness
(OEE)
through
TPM
www.maintenanceworld.com/Articles/Sharmaa/
[4] Paul Dean CEng, 2006 OEE Thoughts, Shire
Systems Limited
[5] Orjan Ljungberg, 1998 Measurement of Overall
Equipment Effectiveness as a basis for TPM
activities, International Journal of Operations &
Production Management, Vol 18 No.5, pp 495507.
5. CONCLUSION
The performance of 72%OEE was attained i.e. an
increase of 28% in OEE which would represent annual
earnings of Rs. 5 lakhs. To achieve this target, efficient
maintenance was in place, Autonomous maintenance
teams were developed and better communication and
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