DEPARTMENT OF MANUFACTURING ENGINEERING TECHNOLOGY

Course Name (Code) Maintenance Planning & Control (BME 3053)

Program Tooling & Production Management
Semester (Session) Semester 1 2023/2024

Course Learning Outcome No. & Assessed for the Assessment

CLO 3: Show concern to achieve continuous improvement in

CLO Assessed
maintenance management. (A3,PLO7)

PLO 7 # Produce the need for professional development and to engage

PLO/LO /SS Evaluated
in independent and lifelong learning environment. (Personal Skills).

Assessment Type ASSIGNMENT 2 Percentage attributed to total mark 10%

(Number)
28th Nov 2023 Submission Date: 12th Dec 2023
Release Date (Week)
(Week 11) (Week 13)

SITI NUR MASTIKA DALIANA BINTI ABDULLAH

NUR AINN NAJWA BINTI MOHD JAMALUDIN
Student Name
NURUL IRFILZATI BINTI RUSLAN
ADRIANA BINTI MUZALE
20B02G004
20B02G005
Matric Number
20B02G010
20B02G013

Administrative Procedure

Prepared by: Checked and approved by:

____________________________ _________________________
Name: Ummi Nazahah binti Roslan Name: Raja Manisa bt Raja Mamat
Date :22/11/23 Date : 22/11/23

Comment(s): Total Marks:

Description:

Total Productive Maintenance (TPM) is a technique which helps us in maintaining and

improving production system through machine, process, and employee which add a positive
value to the organization. In recent years, many companies have attempted to implement this
strategy to maximize equipment’s effectiveness and productivity, and minimize machine
losses.

Instructions:
Select a case study and analyze in details for TPM. In your report, there should be information
comprises the following:

a. Introduction.

b. Issues for discussion (OEE)

c. Comparison of OEE with World Class

d. Benefits of TPM

e. Conclusion.

f. References.

Additional info:
1. Must not exceed more than 10 pages inclusive the cover page.
2. Use Times New Roman 12 and spaced 1.5.
a. INTRODUCTION

Flextronics Manufacturing Sdn Bhd, owned by Flex Ltd., is a leading electronics

manufacturing firm offering services to OEMs in various industries, including design,
engineering, manufacturing, and logistics. Flextronics Manufacturing Sdn Bhd has
implemented Total Productive Maintenance (TPM) to improve equipment reliability and
efficiency. The company encourages Autonomous Maintenance (AM) and Planned
Maintenance (PM) to encourage operators to engage in regular maintenance activities. Focused
Improvement (FI) and Early Equipment Management (EEM) are cross-functional teams
focused on operational inefficiencies. Quality Maintenance (QM) is emphasized to maintain
high-quality output. Education and training programs prepare workers for efficient TPM
implementation. Administrative and Office TPM extend these ideas beyond the factory floor.
Safety, Health, and Environment (SHE) factors are also considered in the strategy. Flextronics'
collaborative efforts aim to foster a proactive maintenance culture and optimize production
equipment efficiency. Overall Equipment Efficiency (OEE) is a crucial indicator in
manufacturing to measure the effectiveness of machinery in a production process, focusing on
three critical factors: availability, performance, and quality, to monitor and improve efficiency.

b. ISSUES FOR DISCUSSION (OEE)

Flextronics Manufacturing Sdn. Bhd. is a global manufacturing services company that

offers design, engineering, and manufacturing solutions for various industries, including
electronics sector. The company has identified challenges related to OEE, including issues with
machine breakdowns, inconsistent performance, and quality concerns.

After all, the company is dealing with problems like machines breaking down too often, not
fixing them efficiently, production inconsistencies, not keeping a close eye on how well things
are going, and not doing enough to prevent mistakes and improve over time. The goal is to
develop a more proactive and efficient approach to keep machines running smoothly, make
high-quality products, and continuously find ways to improve.
1. Availability

a) Frequent Breakdowns and Unplanned Downtime:

• The machines in certain production lines often stop working unexpectedly, the problem
causing the production process to it unplanned downtime.
• The reactive maintenance approach means the machines stay inactive for longer periods
than necessary.

b) Inefficient Maintenance Practices:

• Maintenance practices lack efficiency, contributing to prolonged periods of equipment

inactive for longer than it should be.
• The reactive nature of maintenance exacerbates the impact of breakdowns on overall
production.

c) Lack of Proactive Approach:

• There will get a deficiency in a proactive approach to prevent breakdowns.

• Preventive maintenance strategies are not wee-established to improve machine
availability.

2. Performance

a) Variability in Production Speeds and Output Quality:

• Different manufacturing lines exhibit variability in production speeds and output

quality.
• Inconsistencies hinder the overall performance of the manufacturing processes.

b) Inadequate Monitoring and Analysis:

• Insufficient monitoring and analysis of machine performance data.

• The lack of real time insight hampers the ability to identify and rectify deviations from
optimal standards promptly.

c) Insufficient Training Programs:

• Operators lack comprehensive training programs to ensure consistent and optimal

machine performance.
• Inadequate skill development contributes to variations in operating standards.
3. Quality
a) Increasing Defects and Rework Rates:

• A rise in defects and rework rates is leading to higher production coasts.

• Quality issues are impacting the company reputation and customer satisfaction.

b) Lack of Systematic Quality Checks:

• There a lack of systematic quality checks at various stages of production.

• The absence of rigorous quality control contributes to the increased defect rates.

c) Inadequate Focus on Continuous Improvement:

• A deficiency in the focus on continuous improvement of manufacturing processes.

• The absence of a structured approach to enhance product quality over time.

c. COMPARISON OF OEE WITH WORLD-CLASS

Overall Equipment Effectiveness (OEE) serves as a comprehensive metric for assessing

manufacturing efficiency by considering three key components: Availability, Performance, and
Quality. Availability reflects the impact of downtime loss, accounting for productivity
interruptions caused by factors like equipment failures and changeovers. A world-class
standard is set at 90%, indicating that the process is operational 90% of the planned production
time. The performance takes into account speed loss, considering factors such as machine wear
and misfeeds, with a world-class benchmark of 95%, signifying that the process operates at
95% of its theoretical maximum speed during active periods. Quality measures the impact of
quality loss due to substandard parts, with a world-class level set at 99.9%. These three factors
are multiplied to derive the OEE score, with 85% considered world-class for discrete
manufacturing, providing a comprehensive measure of equipment efficiency and effectiveness.

For Flextronics, a company specializing in electronics manufacturing services,

achieving world-class OEE would involve optimizing various aspects of its production process.
Here's a brief comparison:
1. Availability:
World-class OEE demands exceptional machine availability. Flextronics should aim to
minimize unplanned downtime by addressing issues promptly. This involves
implementing preventive maintenance schedules, utilizing predictive maintenance
technologies, and fostering a responsive maintenance team. Quick identification and
resolution of equipment breakdowns, changeover inefficiencies, and other factors
contributing to downtime are critical.
2. Performance:
Optimizing machine performance is crucial for achieving world-class OEE. Flextronics
should analyze production processes to identify and eliminate bottlenecks, ensuring that
machines operate at their maximum speed. Upgrading outdated equipment,
streamlining workflows, and investing in technologies that enhance production
efficiency contribute to improved performance. Regular performance assessments and
adjustments are essential for sustained high OEE.
3. Quality:
World-class OEE entails producing high-quality products with minimal defects.
Flextronics must focus on improving first-pass yield and reducing rework. This
involves implementing robust quality control measures at every stage of the
manufacturing process. Investing in advanced inspection technologies, employee
training programs, and feedback loops for continuous quality improvement are essential
components of achieving and maintaining world-class quality standards.
4. Overall OEE Score:
To achieve a world-class OEE score of 85% or higher, Flextronics should consistently
monitor and optimize each OEE component, including availability, performance, and
quality. Real-time data analytics, performance dashboards, and regular reviews can
help identify improvement areas. Strategic planning and resource allocation are crucial
for consistently boosting OEE scores.

In conclusion, achieving world-class OEE for Flextronics involves a holistic approach that
addresses availability, performance, and quality. Continuous improvement, supported by
advanced technologies and a proactive organizational culture, is the key to sustaining and
surpassing world-class standards in the competitive field of electronics manufacturing.
d. BENEFIT OF TPM

The comprehensive approach to equipment maintenance and improvement known as Total

Productive Maintenance (TPM) takes into account all organizational levels. Implementing
TPM is essential to maximizing the efficiency of manufacturing equipment in the context of
Flex, a global provider of services for electronics manufacturing. the numerous advantages that
TPM offers Flex, tackling the underlying reasons for malfunctions, flaws, and other operational
difficulties. There are several benefits to Flextronics:
1. Downtime Reduction Through Proactive Maintenance
To improve Overall Equipment Effectiveness (OEE) by methodically
decreasing downtime, Total Productive Maintenance (TPM) is a crucial
component. A dedication to reducing unplanned malfunctions is highlighted by
Flex's emphasis on proactive and preventive maintenance. Flex can establish a
comprehensive preventive maintenance program that involves regular
equipment inspections and early problem identification by following TPM
guidelines. That being said, being proactive goes beyond conventional
techniques. Flex can foresee possible failures before they happen by utilizing
cutting-edge technologies like predictive analytics and condition monitoring.
With a more planned downtime and a more streamlined and effective production
process, the company can address problems in its early stages thanks to this
forward-thinking approach.
2. Quality Assurance Through Root Cause Analysis
Flex's goal of constant product quality and TPM's dedication to
resolving defect causes go hand in hand. Flex makes sure that every electronic
component fulfils or surpasses the exacting standards of quality anticipated in
the industry by keeping its equipment in top working order. TPM includes a
strong root cause analysis system in addition to standard maintenance. To do
this, all defects must be thoroughly examined to determine their underlying
causes. Flex can use this TPM feature to implement focused enhancements that
will eliminate defect sources and improve the overall quality of electronic
components and finished goods. Flex increases customer satisfaction and brand
confidence by lowering errors and rework, which guarantees a higher degree of
quality assurance.
3. Proactive Maintenance for Minimized Downtime
Flex takes a proactive approach by implementing the concepts of Total
Productive Maintenance (TPM) to reduce downtime and breakdowns. To
prevent unplanned downtime, TPM lays a strong emphasis on scheduled and
planned maintenance activities. This entails putting into practice thorough
preventive maintenance schedules at Flex that specify standard procedures to
be performed on manufacturing equipment. To keep machinery operating at
peak efficiency, these schedules are painstakingly created to handle possible
problems before they become serious ones. As a fundamental component of this
strategy, routine inspections enable Flex to carry out comprehensive evaluations
of the state of the equipment. Additionally, the incorporation of condition-based
monitoring technologies offers real-time insights into the operation of crucial
components, facilitating preventative measures to address possible problems
and maintain them.
4. Root Cause Analysis for Enhanced Product Quality
Flex strategically applies Total Productive Maintenance (TPM)
concepts with a focus on root cause analysis to achieve higher product quality.
As a methodical approach, TPM entails a careful analysis of flaws to find and
fix their root causes. Flex can apply an organized root cause analysis approach
that is compliant with TPM procedures. This calls for a cooperative effort in
which cross-functional teams examine the variables that lead to defects. Flex
obtains important insights into possible flaws in the machinery, systems, or
manufacturing processes by comprehending the underlying causes. A
continuous cycle of improvement in product quality is ensured by the
implementation of targeted corrective actions made possible by this systematic
analysis.
5. Empowering the Workforce through Training and Skill Development
Flex proactively conducts training programs intended to improve staff
members' equipment maintenance skills by TPM theories. Beyond conventional
models, these training programs include a thorough comprehension of the
principles of TPM, equipment functions, and manufacturing processes. Flex
fosters a sense of ownership and competence among its staff members by
making ongoing investments in skill development and training, which also
 provides its workers with the technical know-how required for efficient
maintenance.
Employees play a crucial role in the overall success of TPM
implementation as they become proficient in equipment maintenance through
targeted training. The training initiatives promote a shared responsibility culture
in which all staff members are encouraged to actively participate in the upkeep
and repair of company property. This change in perspective, which emphasizes
that everyone, regardless of role, plays a crucial part in ensuring the reliability
and efficiency of manufacturing processes, is in line with the collaborative
nature of TPM. Additionally, Flex's investment in training programs shows its
dedication to the professional development of its workforce, fostering an
environment where innovation and adaptability are valued across the board.

e. CONCLUSION
Flextronics Manufacturing Sdn Bhd has implemented Total Productive Maintenance
(TPM) to address issues affecting Overall Equipment Effectiveness (OEE), including
machine breakdowns, inconsistent performance, and quality concerns. The company aims
to achieve world-class OEE standards by focusing on availability, performance, and
quality. TPM benefits Flextronics by reducing downtime, ensuring product quality through
root cause analysis, and empowering the workforce through training and skill development.
The company emphasizes continuous improvement, advanced technologies, and a
collaborative organizational culture to surpass world-class standards in the competitive
electronics manufacturing sector.

f. REFERENCE

[1] https://www.tecnest.it/en/flex-tpm-advantages/1482
[2] https://www.reliableplant.com/Read/32240/reducing-downtime-with-predictive-
maintenance
[3] http://www.hi-flex.com/parts_services/maintenance_training.php
Appendix 1:

PLO 7 # Produce the need for professional development and to engage in independent and lifelong learning environment. (Personal Skills).

Level Mark
No Criteria
Very Poor 1 Poor 2 Average 3 Good 4 Excellent 5
1 Ability to Information Information Information
collect and gather is not gather are useful gather are very
manage relevant and and able to useful and
information require maximum use/manage the extraordinary
independently guidance and information to /high quality
assistance to the context of sources and able
use/manage the the related study to interrelated
information to given the information
the related study to the given
given study with extra
justification
independently
Ability to Unable to develop Develop Develop
construct justification/state justification/stat justification/stat
coherent a n d ment/analy ement/analy ement/ana
sis/judgment sis/judgement lysis/judgement
focused structure
2 accordance to its coherently and critically in a very
flow and properly interesting way
improper structured and fully
structured organised and
structured

Total
10
Grand Total
10