Development of a maintenance schedule plan to improve the equipment efficiency of an industry: a case study

Abstract

The aim of this study is to implement Total Productive Maintenance (TPM) in a continuous injection molding industry. By implementing TPM, the industry can increase their Overall Equipment Effectiveness (OEE) and productivity. Before implementing TPM, overall equipment efficiency, availability rate, performance rate, and quality rate of the injection molding machine were 74.9%, 88.54%, 88.5%, and 95.6%, respectively. It needs to be improved for good operating condition of machines. In this paper, some tools are suggested to improve their productivity and maintenance procedure. These tools are cause and effect diagram, Pareto chart, WWBLA, and preventive maintenance schedule. TPM program is to change the culture of the company maintenance policy with involvement of all employees toward the maintenance system of the company. Through the proper planning of maintenance schedule, productivity can be improved. This schedule helps to maintain machines in good operating conditions as well as a good OEE value, and a world class standard OEE is achieved.