Enhancing Manufacturing Process through Prioritizing Total Productive Maintenance Pillars
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Date
2019-04
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Addis Ababa University
Abstract
Large number of framework of Total Productive Maintenance (TPM) pillars have
been proposed by different authors in TPM literature. However, most of them are
based on studies done in countries such as Japan, Italy, USA, China and India.
Thus, this study aims to evaluate selected TPM pillars contribution towards
manufacturing performance on Nile Sole Factory. Production, Downtime, reasons
of downtime, scrap level, and rework data is collected from the Nile sole factory
and analyzed to see the current performance of the company. A survey
methodology is used where questionnaires are distributed to 35 employees of the
factory with the resulting response rate of 97 %. Using descriptive statistics tools,
the correlation between TPM Pillars and manufacturing performance dimension
has been calculated. The Pillar most emphasized on the survey is planned
maintenance while the least emphasized Pillar is on office TPM. To support the
result from the output of descriptive statistics, AHP (analytic Hierarchy Process) is
used. The study reveals that the TPM Pillar – focused improvement, planned
maintenance, autonomous maintenance and Training and education have
significant contribution towards manufacturing performance such as lower cost,
higher equipment availability, strong delivery and increased Flexibility. A new
model has been developed in which the last Pillar Safety Health and environment
(SHE) diffused in all the four pillars. This pillar has an intangible benefits in
making employers safe and well and indirectly impact the productivity. All selected
four pillars have activities that help safety of the shop floor when fully
implemented. Sustaining safety activities in all the pillars will play significant role
in making the working environment safe working place.
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Keywords
Productive Maintenance Pillars, Manufacturing Process