Overall Equipment Effectiveness Enhancement through Total Productive Maintenance: A Case of Mugher Cement Factory
No Thumbnail Available
Date
2019-10
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
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.
Description
Keywords
Total Productive Maintenance, Overall Equipment Effectiveness, Availability, Autonomous Maintenance