Overall Equipment Effectiveness Enhancement through Total Productive Maintenance: A Case of Mugher Cement Factory

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Date

2019-10

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Addis Ababa University

Abstract

Total Productive Maintenance program is an excellent maintenance technique with aim of increasing overall effectiveness of an industry by maximizing resource utilization. It attempts to involve all employees in maintenance system of a company. The purpose of this study is to enhance overall equipment effectiveness through total productive maintenance in the case company Mugher Cement Factory. In Mugher Cement Factory, the average overall equipment effectiveness for the period 2014-2018 was found to be 22.2% which is below the world class target of 85%, this decrement was due to machine frequent failures, lack of integration of maintenance staff and other departments, lack of inspection and lack of quality spare parts. In order to undertake this study, both primary and secondary sources of data were used. The primary data were collected by using questionnaire, interview, observation and discussion with target groups. A survey questionnaire was prepared and distributed to 25 respondents and the responses are analyzed using statistical techniques using SPSS. A correlation was also performed in order to indicate the interrelationship between TPM pillars and manufacturing performance of the company. Besides, secondary data was gathered from the company reports (yearly and monthly reports, strategic plan and log sheet). Based on the results from the analysis and evaluating the existing maintenance practices of the company, a TPM implementation framework and guideline was developed. In addition to the TPM framework, autonomous maintenance guideline that can be used as a foundation to introduce Total Productive Maintenance in Mugher Cement Factory on the improvement of availability and OEE is proposed. Even though TPM is not a new concept, to the best knowledge of the researcher, the introduction of the concept into Ethiopian Cement Industries especially In Mugher Cement Factory is not covered well. Therefore, this paper will fill this gap.

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Keywords

Total Productive Maintenance, Overall Equipment Effectiveness, Availability, Autonomous Maintenance

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