Project Justification

Increase OEE

OEE is an indicator that measures the effectiveness of industrial machinery, used as a key tool within a culture of
continuous improvement. Its acronym corresponds to the English term "Overall Equipment Effectiveness" or
"Global Efficiency of Production Equipment".

What a high OEE provides to the company (advantages)?

• Return on investment (ROI)

• Competitiveness

• Machinery performance improvement

• Increases process quality

• Ability to measure and decide

• Discover the “Hidden Factory”

• Facilitates the work of all people involved in the manufacturing process

• Reduces machinery repair costs

• Scalability
 Project Justification
OEE aimed targets for KPL

The middle table compares the current state with a realistic scenario. In order to accomplish this goal, the company’s current OEE requires a
improvement of 5.06%, which will be achieved through equal gains in availability and productivity (2.5%).
The Six Big Losses
The main losses that impact OEE

Losses: Limiting the

equipment efficiency

Equipment Equipment
Defect Loss
Downtime Loss Performance Loss

• Equipment failure
• Minor stoppage &
• Setup and • Quality defects &
idling losses
adjustment loss rework loss
• Speed loss
• Startup loss

Six Big Losses

OEE
OEE and the Six Big Losses

Planned Shift Duration

No production
A Planned Production Time Planned

B Actual Running Time Stoppages

C Theoretical Machine Production Rate

D Theoretical Machine Production Rate Speed Loss

E Pieces Produced

F Good Parts Wastage

Startup Loss
Minor
stoppage & Setup and

Quality
idling
losses
adjustment
loss Six Big Losses
defects &
Equipment
rework loss Speed Loss Failure

OEE = (B/A)*(D/C)*(F/E)
Future Situation
Future Situation
How to achieve the proposed targets

Through the development and implementation of a TPM system firstly focusing the circular looms at D19.

The TPM system will contemplate the following TPM’s pillars:

The goal of TPM focuses on improving corporate culture

through improvement of human resources and plant
equipment. The Japan Institutes of Plant Maintenance
TPM
(JIPM) has put forward the five goals of TPM which are

Quality Maintenance
Training & Learning

Safety, healthy and

the minimum requirements for the TPM development:
Initial Control
Improvement

Management
Maintenance

Maintenance
Autonomous

Environment
Improving equipment effectiveness
Planned
Specific

Improving maintenance efficiency

Early equipment management and maintenance

prevention

5S Training to improve the skills of all people

People involved

Involving operators in routine maintenance

The key for a TPM success are the people that will execute the Autonomous
Maintenance, The Planned Maintenance and the Training & Learning actions.
It’s needed to change the mind set of the operators from machine’s operators
to machine’s conditions responsible.
Future Situation
Why TPM?

Implementing Total Productive Maintenance (TPM) in the manufacturing industry has emerged as an
important operational strategy to overcome production losses due to equipment inefficiency. TPM is an
innovative approach, which holds the potential for enhancing the efficiency and effectiveness of
production equipment by taking advantages of abilities and skills of all individuals in the organization.
TPM integrates Maintenance and Operations, by coordinating their efforts to perform predictive and
preventive maintenance in a proactive team effort. It focuses on maximizing the Overall Equipment
Efficiency (OEE) with the involvement of each and everyone in the organization. TPM and its implications
received prestigious worldwide recognition in achieving the ultimate Zero Defects and Zero Breakdown
targets.
Future Situation
How TPM can help on the OEE target’s achievement?

TPM is a global strategy to increase competitive advantage, providing directions so that a company can
achieve world class organization and become the leader in competitions. Some benefits of the TPM are:

Improvement of OEE by 14%-15%

Reduced stocks by 45%-58%

Increased output of production by 22%-41%

Reduced rejection from customers by 50-75% This data is according to books and
Reduced accidents by 90-98% academic papers, and they will be used
Reduced maintenance costs by 8%-27% only as a guide.
Reduced defects and reworks by 65%-80%

Reduced breakdowns by 65%-78%

Reduced energy costs by 8%-27%

Increased employees` feedback by 32%-65%

Source: Ahuja, I.P.S., & Kahamba, J.S. (2008). Total Productive Maintenance, Literatur review and direction
Future Situation
What are the departments in charge of TPM?

TPM needs to be a concept intrinsic to every department, from the lower hierarchical layer in an
organizational structure until the top one.

There are two main departments responsible for running the TPM actions and procedures:

TPM

Quality Maintenance
Training & Learning

Safety, healthy and

Initial Control
Improvement

Management
Maintenance

Maintenance
Autonomous

Environment
Planned
Specific

5S
People

Production Maintenance
Department Department
Future Situation
KPL TPM’s Main Objectives

1. Change the culture of the company`s maintenance policy by involvement of all employees toward the
maintenance system of the company

2. Make the equipment`s available under acceptable conditions

3. Increase and maintain OEE by increasing Availability, Productivity and Quality

4. Ensure the safety of human and nature

5. Prolong the equipment`s period of use

Cost to
Capacity
operate
Future Situation
KPL TPM’s Framework
Some TPM Best Practices
HELP CHAIN
1 2 3

If the problem still remains, then another

If the operator is not able to fix the As soon as the maintenance team signal is triggered to call manager’s
equipment, he must contact the visualizes the signal, they must send attention;
maintenance team through a signal specialized workers to solve the problem;
detector;

5 4

Another solution is contacting the If that is not enough, then directors are
equipment’s supplier in order to fix the contacted to take a decision
machinery;
ANDON – BASIC CONCEPT

Each machine should have a signal system in order to

monitor the equipment’s functioning based on:

The equipment is running well

The equipment requires set up or simple

adjustments

The equipment is not running

ANDON – ADVANCED CONCEPT
Each machine should have a signal system
associated with a clock in order to monitor the
equipment’s functioning based on:

Equipment is running well

Shortness of tape 00:30

Equipment is in maintenance 01:30

Equipment requires set up 00:15

Equipment breakdown NOW!

The ANDON program advanced comprehends a visual system linked with a clock. Every time a visual alert is
activated, the clock is triggered to start counting according to a program specification for that kind of problem.
When the time is out, the clock rings and a warning is sent to the maintenance monitoring board. Each type of
problem requires a different time for the clock, which will be scheduled conform specification. This way, it is
possible to the maintenance team control every change occurrence in the equipment.
ANDON – BASIC CONCEPT
MAINTENANCE BOARD
INSPECTION DEVICE FOR HIDDEN POINTS

Machinery’s design

The equipment’s design must

facilitate the access to the
electrical panel, hydraulic unit
and valves. Moreover, it must
Operation’s
allow the operation visibility. visibility
Electrical pannel
installed in the
back side

Free access to
the valves
INSPECTION DEVICE FOR HIDDEN POINTS

Using fans to control the equipment’s functioning

If the fan is spinning then the

equipment’s internal device is
working;

If the fan is not spinning then

equipment’s internal device is not
working properly
INSPECTION DEVICE FOR HIDDEN POINTS

Adhesive temperature strips are sensible to fluctuations on temperature;

They can be used to control the equipment’s heating;

Normal levels of operation must be indicated as well as warning ranges;

Normal levels of
operation
INSPECTION DEVICE FOR HIDDEN POINTS
Using acrylic cover to control the equipment’s functioning

The use of acrylic cover in the equipment facilitates the maintenance monitoring as
it increases accessibility to internal parts of the equipment.

BEFORE AFTER
INSPECTION DEVICE FOR HIDDEN POINTS

Using acrylic cover to control the equipment’s functioning

The use of acrylic cover in the equipment facilitates the maintenance monitoring as
it increases accessibility to internal parts of the equipment.

BEFORE AFTER