Autonomous Maintenance Case Study

The automotive sector constitutes one of the most demanding activities in the global market, since it requires a constant increase in productivity, both in the automobile industry as well as in the companies whose manufacture its components. This sector is currently set within an economic framework where there is a relentless search for costs reduction and an increase in productivity with minimal investment. In order to meet these requirements, companies have sought to optimise their products and processes to ensure higher profits. This study was developed with the purpose of enhancing procedures in the maintenance sector regarding a company which supplies air-conditioning tubes to the automotive sector. The main objective was to increase its machines and equipment availability through the implementation of autonomous maintenance. Due to the undertaken improvements, there was a 10% increase in the monthly indicator of equipment availability on line AA3 at the company where the study was carried out. This, in turn, resulted in an increase of 8% in OEE (Overall Equipment Effectiveness) during the same time period, which was chiefly due to a reduction both in machine breakdown rates, as well as in the MTTR (Mean Time To Repair) on the same line.

The semiconductor industry has gone through significant changes in the last decade. Competition has increased dramatically. Customers focus on product quality, product delivery time and cost of product. Because of these, a company should introduce a quality system to improve and increase both quality and productivity continuously. Total productive maintenance (TPM) is a methodology that aims to increase the availability of existing equipment hence reducing the need for further capital investment. Investment in human resources can further result in better hardware utilisation, higher product quality and reduced labour costs. The aim of the paper is to study the effectiveness and implementation of the TPM programme for an electronics manufacturing company. Through a case study of implementing TPM in an electronics manufacturing company, the practical aspects within and beyond basic TPM theory, difficulties in the adoption of TPM and the problems encountered during the implementation are discussed and analysed. Moreover, the critical success factors for achieving TPM are also included based on the practical results gained from the study. After the implementation of TPM model machine, both tangible and intangible benefits are shown to be obtained for equipment and employees respectively. The productivity of the model machine increased by 83%.

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