TPM Implementation and OEE Evaluation in Manufacturing Industries an Empirical Study

Total Productive Maintenance is practical technique aimed at maximizing the effectiveness of facility that we use within our organization .Total productive maintenance establishes a system of productive maintenance, covering the entire life cycle of equipment, covers all department, involves participation of all employees from top to bottom and promotes small group autonomous activities. During high growth era companies are making technical progress in automation and centralization of the plants, which needs large amount of manual work to maintain the automation systems. The strategy of maintaining the equipment of a plant is crucial for the effectiveness of manufacturing. And, as the competitive environment in the world continues to increase the pace, our project work intends to help companies to look for new strategies to save on costs, develop employees to face future challenges and bring about a new culture at work place. To carry out successful implementation of our work, firstly, literature review was done thoroughly to understand the underlying concepts of TPM. Further, empirical study was conducted about the sophisticated Printing Press machines & Packaging machines based on real time data and analysis was done to obtain achievable results. Finally questionnaires were distributed to evaluate information on successful implementation of TPM in the industry. Results obtained through the empirical study reveals the varying trends in the Overall Equipment Effectiveness (OEE) and Total Productivity of the machines taken up for the study. The average values of OEE were found to lie between the ranges of 15% to 60% against world class standards of 85% and Total Productivity (TP) varies between 0.09 to 0.34. The results highlight the major causes resulting in the downtime and decrease in the productivity. A comparative study between World Class industries where TPM has been implemented and industries which do not follow. TPM identifies the various problems leading to decrease in the overall efficiency of the industry and provides valuable suggestions focusing on the benefits and methodology for implementing TPM in industries.