Mechanical Engineering:

Title:           Study of overall performance of an aluminium utensils producing company in India by total productive techniques
Authors:      Pradeep Kumar, Raviraj Shetty, Divakara Shetty, Lewlyn L.R. Rodrigues
Abstract:     Total Productive Maintenance (TPM) is becoming an industrial standard and it is an approach to optimize the effectiveness of production means in a structured manner. The Indian manufacturing industry has witnessed irrepressible competition in the recent times in terms of low costs, improved quality and diverse products with superior performance. Indian entrepreneurs have understood the significance of improving maintenance performance in organizations. 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 based on real time data and analysis was done to obtain achievable results. Finally questionnaires were distributed to assess 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 of Udaya Aluminum Industries., Manipal, taken up for the study. The average values of OEE were found to lay between the ranges of 47% to 61% against world class standards of 85%. And Overall Productivity ranges 0.7 to 1.57, but Human Productivity varies from 37 to 45 Machine Productivity varies between 74 to 90 and Material Productivity varies between 0.8 to 1.67. The fluctuation of productivity is there which shows the instability of plant efficiencies and also represents the irregularities in manufacturing, operator error, rework, rejection, incorrect assembly, speed loss and other losses. The results highlight the major causes resulting in the downtime and decrease in the productivity. Although the OEE can be improved a bit to make it more productive by reducing loss. Losses such as break down, maintenance, start-up defects, process defect and total defective output can be reduced and hence there can be significance increase in OEE and productivity. A comparative study between World Class industries where TPM & TQM 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 &TQM in industries.

Keywords:   Total Productive maintenance (TPM), Total Quality Management (TQM), Overall Equipment Effectiveness (OEE) and Productivity.
Pages:         070-076

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