Query: maintenance strategies on OEE

Candidate papers:

abstract: In an environment of intense global competition, both creative and proven strategies need to be considered in order to bring about the effectiveness and efficiency in manufacturing operation. Total Productive Maintenance (TPM) is one of the effective maintenance strategy in enhancing the equipment effectiveness and to achieve a significant competitive advantage. This research paper addresses the impact of three TPM pillars namely planned maintenance (PM) autonomous maintenance (AM) and focused maintenance (FM) on overall equipment effectiveness (OEE) of die attach equipment in the production line of semiconductor industry. The effect of TPM on the OEE is also investigated depending on the equipment types, in where die attach process consist of two models CANON and ESEC. The primary data was collected from an organization's database and was analysed by SPSS V23. The preliminary results of the analysis showed that the performance of OEE in ESEC is better than the CANON after the implementation of TPM. The analysis also showed that out of the three TPM practices deployed, planned maintenance of equipment by production and maintenance team played the biggest role in increasing the equipment effectiveness. In conclusion, this study provides insights the importance of implementing TPM in order to succeed in a highly demanding market arena.
author_names: Soo-Fen Fam

Ser Lee Loh

M S Haslinda

Heri Yanto

Linda Mei Sui Khoo

Diana Hwa Yieng Yong
title: Overall Equipment Efficiency (OEE) Enhancement in Manufacture of Electronic Components Boards Industry through Total Productive Maintenance Practices
year: 2018

abstract: Persaingan yang semakin tinggi menuntut perusahaan untuk bisa beroperasi dengan produktivitas yang maksimal melalui penerapan berbagai strategi optimasi produksi diantaranya adalah TPM Total Productive Maintenance TPM sendiri menurut Ahuja (2008) merupakan kunci kesuksesan dari setiap manufacturing optimization strategies karena tanpa mesin yang andal semua program optimasi produksi/manufaktur tidak akan bisa berjalan dengan sempurna. Salah satu metode mengukur tingkat keberhasilan penerapan TPM adalah melalui pengikuran nilai Overall Equipment Effectiveness (OEE) PT. TES merupakan perusahaan yang bergerak di bidang industri pangan yaitu produk susu sereal. Permasalahan terbesar yang dihadapi perusahaan saat ini ialah tingginya downtime mesin wrapping Efek dari downtime tersebut adalah menurunnya kecepatan dan performa mesin sehingga menyebabkan rendahnya OEE. Untuk itulah penelitian ini dilakukan. Data dikumpulkan langsung di lapangan selama 12 minggu (3 bulan) Langkah selanjutnya adalah menghitung nilai OEE diikuti dengan analisa six big losses serta dianalisa dengan menggunakan pareto chart fishbone diagram dan regresi berganda. Dari pengolahan data diperoleh nilai OEE tertinggi yaitu terdapat pada periode minggu ke 8 dengan persentase sebesar 70,70% sedangkan nilai OEE terendah terdapat pada periode minggu ke 8 yaitu sebesar 58,50% dengan OEE rata rata 68.31% Faktor six big losses yang paling berpengaruh terhadap rendahnya OEE mesin Wrapping High Speed Line 4 diketahui dengan analisa korelasi berganda adalah variabel X2 yaitu Breakdown loss dengan R sebesar 0,46.
author_names: Herry Agung Prabowo

Milla Agustiani
title: EVALUASI PENERAPAN TOTAL PRODUCTIVE MAINTENANCE (TPM) MELALUI PENDEKATAN OVERALL EQUIPMENT EFFECTIVENESS (OEE) UNTUK MENINGKATKAN KINERJA MESIN HIGH SPEED WRAPPING DI PT. TES
year: 2018

abstract: Manufacturing strives to reduce waste and increase Overall Equipment Effectiveness (OEE) When managing machine tool maintenance a manufacturer must apply an appropriate decision technique in order to reveal hidden costs associated with production losses, reduce equipment downtime competently and similarly identify the machines' performance. Total productive maintenance (TPM) is a maintenance program that involves concepts for maintaining plant and equipment effectively. OEE is a powerful metric of manufacturing performance incorporating measures of the utilisation, yield and efficiency of a given process, machine or manufacturing line. It supports TPM initiatives by accurately tracking progress towards achieving "perfect production." This paper presents a review of maintenance management methodologies and their application to positional error calibration decision making. The purpose of this review is to evaluate the contribution of maintenance strategies, in particular TPM, towards improving manufacturing performance, and how they could be applied to reduce downtime due to inaccuracy of the machine. This is to find a balance between predictive calibration, on machine checking and lost production due to inaccuracy. This work redefines the role of maintenance management techniques and develops a framework to support the process of implementing a predictive calibration program as a prime method to supporting the change of philosophy for machine tool calibration decision making. Keywords maintenance strategies, down time, OEE, TPM, decision making, predictive calibration.
author_names: Abubaker Shagluf

Andrew Longstaff

Simon Fletcher
title: Maintenance strategies to reduce downtime due to machine positional errors
year: 2014

abstract: In the modern industrial world, effective role of maintenance activities in the survival of organizations and enhancing their productivity is undeniable. Variety of equipments in the industrial organizations and their exclusivities in terms of longevity and failures modes, clear the importance of choosing a strategy for the maintenance of any equipment. Thus, knowing the type of the failure is so important for maintenance manager and engineers. Important introduced indicators in this domain such as indicator of reliability, MTBF and MTTR can be used to predicting and detecting approximate failure time and analyzing life cycle status. On the other hand, due to fluctuating time of system availability because of work continuity and loss of a performance indicator, by combining RCM indicators and Overall Equipment Effectiveness (OEE) indicator the most compatible strategy could be chosen. The aim of this article which differs from other studies in this field is to apply a composed indicator, including different parameters of RCM, which is obtained based on the equipment life status.
author_names: Mohammad Zadhoosh

Amir Afshin Fattahi
title: Simultaneous effect of RCM key indicators, related to equipment lifecycle for maintenance strategies (in production systems)
year: 2015

abstract: Process output and profitability of the operations are mainly determined by how the equipment is being used. The production planning, operations and machine maintenance influence the overall equipment effectiveness (OEE) of the machinery, resulting in more 'good parts' at the end of the day. The target of the predictive maintenance approaches in this respect is to increase efficiency and effectiveness by optimizing the way machines are being used and to decrease the costs of unplanned interventions for the customer. To this end, development of ad hoc strategies and their seamless integration into predictive maintenance systems is envisaged to bring substantial advantages in terms of productivity and competitiveness enhancement for manufacturing systems, representing a leap towards the real implementation of the Industry 4.0 vision. Inspired by this challenge, the study provides an approach to develop a novel predictive maintenance platform capable of preventing unexpected breakdowns based on integrated strategies for extending the operating life span of production systems. The approach and result in this article are based on the development and implementation in a large collaborative EU funded H2020 research project entitled Z Bre4k, i.e. Strategies and predictive maintenance models wrapped around physical systems for zero unexpected breakdowns and increased operating life of factories.
author_names: Gokan May

Nikos Kyriakoulis

Konstantinos Apostolou

Sangje Cho

Konstantinos Grevenitis

Stefanos Kokkorikos

Jovana Milenkovic

Dimitris Kiritsis
title: Predictive Maintenance Platform Based on Integrated Strategies for Increased Operating Life of Factories
venue: APMS
year: 2018

abstract: Abstract Planned and unplanned downtime emanating from maintenance, production, and operational function adversely affects the performance of manufacturing plants. This paper develops joint maintenance, production and process/operations control policies integrating Opportunistic Maintenance (OM) which takes advantage of external (operational related downtimes) and internal maintenance opportunities. The study quantifies the effects of maintenance strategies on the plant's performance, here, the overall equipment effectiveness (OEE) which importantly presents insights on maintenance decision support for production facilities facing significant operational related stoppages. The study integrates both economic and structural dependence and models the influence of alternative maintenance actions of different maintenance policies, on product quality. The developed model is validated by applying to a multi unit repairable, imperfectly maintained raw meal grinding system of a cement plant. From the simulation modelling results, integration of the opportunistic maintenance approach, complementary to corrective, preventive and condition based maintenance strategies, show more enhanced equipment performance, as measured through the OEE.
author_names: James Wakiru

Liliane Pintelon

Peter N Muchiri

Peter Chemweno
title: Integrated maintenance policies for performance improvement of a multi unit repairable, one product manufacturing system
year: 2020

abstract: Maintenance plays a significant role in asset management of power organisations. Utilisation of right maintenance strategy contributes to high availability and reliability of power plants. Inexperience in implementing modern maintenance programmes and lack of utilising effective maintenance strategies results in bad maintenance practices, low productivity, and a negative impact on financial performance. Thus, effective maintenance strategies become a complex task that deals with multifaceted nature of actions like irregular and uncertain nature. Total Productive Maintenance (TPM) is an ideal approach to support the development and implementation of operation performance improvement. It systematically aims to achieve zero breakdowns, zero defects and zero accidents in order to have high overall equipment effectiveness (OEE) Implementation of TPM programme needs strategic planning. However, there has been almost no research applied in this area within Middle East power plants. In the power sector of Abu Dhabi, assets management is extremely significant, and it thus requires efficient and effective support of equipment management. The aim of this paper is to investigate technical barriers to successful TPM implementation in the Abu Dhabi power industry. The study has been conducted in the context of a leading power company in the UAE. Questionnaires were distributed with 224 employees, including engineers, maintenance planners, technicians, and operators using a postal questionnaire. The findings of this research identified six key barriers, thus: maintenance policy and methods; maintenance resources, tools and spare parts; computerized maintenance management system (CMMS) housekeeping; participation of autonomous maintenance and maintenance audits. With respect to the understanding of these barriers and obstacles in TPM implementation, the findings can contribute towards improved equipment operations and maintenance in power organisations.
author_names: Abdulla Alseiari

Peter Farrell

Yassin Z Osman
title: Technical and Operational Barriers that Affect the Successful Total Productive Maintenance (TPM) Implementation: Case Studies of Abu Dhabi Power Industry
year: 2020

abstract: The exploration for improving productivity in the current competitive global environment since customers are becoming more and more quality centered and demands among customers are increased. To meet customer demand industries must work with efficiency oriented. One of the way to increase efficiency and productivity is to increase the OEE (Overall Equipment Effectiveness) of the plant or machines. OEE can be improved by continuous improvement of TPM (Total Productive Maintenance).This review study discusses an application of industrial engineering techniques such as TPM ,OEE. Total productive maintenance (TPM) is one of the most popular maintenance strategies to ensure high machine reliability, maintaining equipment in top working condition to avoid breakdowns and minimize downtimes in the manufacturing process. Keywords Total productive maintenance, Overall equipment effectiveness Vol. XI Issue No. 6 June 2018
author_names: Darpit N Gandhi

Vivek A Deshpande
title: A REVIEW OF TPM TO IMPLEMENT OEE TECHNIQUE IN MANUFACTURING INDUSTRY
year: 2018

abstract: Nowadays, with changes in the world scenario in the midst of globalization, the emergence of new technologies and new forms of organization have been driving companies to become more competitive, to redesign their strategies and operations processes, especially with efficient use of all its resources. Maintenance management is fundamental in this process in order to maintain the proper functioning of production processes. Previous studies on the efficiency analysis through indicators have investigated the application of the OEE (Overal Equipment Eficient) indicator in several contexts. The objective of this research was to analyze the impact of the lack of spare parts on the production efficiency using as metric the OEE indicator. For that, a case study was carried out in a chemical company that uses industrial operations in a continuous way. The results indicated that the lack of an essential part for the operation of a machine impaired the entire productive chain in which it is inserted.
author_names: Everaldo Francisco da Silva

Luis Fernando Ferreira Damasceno

Adriano Manicoba da Silva

William de Paula Ferreira
title: Impact of missing spare part on production efficiency: An analysis with the OEE indicator
year: 2018

abstract: The Electrical and Electronics (E&E) industry continues to be a key driver of Malaysia's Industrial development and contributes significantly to GDP growth, export earnings, investment, and employment. Malaysia has become a major global manufacturing hub for the E&E industry and four decades and continues to be a preferred E&E investment destination. In order to sustain and stay competitive, the Malaysian semiconductor companies are urged to implement world class maintenance techniques that will improve equipment utilization and thus reducing capital expenditure. Total Productive Maintenance (TPM) is one of the effective maintenance strategies for enhancing the overall equipment effectiveness (OEE) to achieve a significant competitive advantage. The aim of the study is to determine the effectiveness of TPM to improve OEE in the E&E industry. This study used the real time data for two types of die attach equipment models, namely CANON and ESEC. The data was collected from an E&E company in Malaysia. The real time data was recorded by software known as Global Operator User Interface (GOUI) system. GOUI system captures the real time data directly from the machine. The result shows that the implementation of TPM gives a significant difference in OEE for both different equipment models. In addition, this study also shows that the three TPM practices namely planned maintenance, autonomous maintenance, and focused maintenance are able to explain 91.2% of the total variation of OEE in the E&E industry.
author_names: Soo-Fen Fam

Dedy Dwi Prastyo

Ser Lee Loh

Sekar Utami

Diana Hwa Yieng Yong
title: Total Productive Maintenance Practices in Manufacture of Electronic Components Boards Industry in Malaysia
year: 2018