Productivity Improvement- Application of TPM and layout design

Abstract: In this thesis, with a discussion on concepts and principles of total productive maintenance(TPM), overall equipment effectiveness (OEE), efficient layout design, maintenance activitiesand scope of development, a detailed report is provided on real scenario of a drilling pipes andaccessory manufacturing factory Driconeq Production AB, Sweden. Total ProductiveMaintenance (TPM) is a maintenance program which involves a newly defined concept formaintaining plants and equipment. That is why, TPM pillars, improvement plan andimplementation routes are described with example of real facilities so that the company will beable to implement those tools and tactics by following step-by-step procedures.Calculating the overall equipment effectiveness (OEE) rate is a crucial element of any seriouscommitment to reduce equipment- and process-related wastes through total productivemaintenance (TPM). Clear picture of big losses are easily identified by using OEE and the biglosses can be eliminated by small modification or change.Effective layout design reduces number of intercellular movement or inter-machine movement.This movement has direct impact on material handling time and cost. In this master thesis, thecell formation and layout design are considered simultaneously. The objective of cell design isto make use of the valuable information about the flow patterns for the various jobs in amanufacturing system and obtain relevant performance measures for the cell design and layoutproblem.It is observed that the condition can be improved with a change in the existing design. Therefore,some necessary changes were recommended and the machine jigs/fixtures were re-designed.This paper later demonstrates the design and modification of small parts which can protect frombig time losses.The author also prescribed some maintenance activities for asset care and a training manualchecklist for all the employees to make efficient and safe working environment. At last, of all, inthis thesis, author stressed on standard work practice to achieve world class performance and utilization of hidden capacity.