An Application on the Measurement and Improvement of Overall Equipment Efficiency in a Production Line

Öz

Total productive maintanance work is an important step of lean production philosophy. Total productive maintanance can be defined as the whole of the works performed to increase the productivity of the equipments that are used in production activities and  to prevent the defected parts that result from the probable machine error.  We come across the term of Overall Equipment Efficiency for the measurement of the lean production and total productive maintenance implementations. This term helps us measure how efficiently the machine and equipment are used in the workplace (uygun gibi). In this study, Total productive Maintenance was mentioned in terms of productivity in businesses the importance of overall equipment efficiency was expressed for businesses and the values of overall equipment efficiency of the production line  in a pasta production plant were calculated.  As a result of this calculation, it was determined that the machine stoppage was not low enough and some improvements were made. In the last chapter, the values of Overall Equipment Efficiency were compared to ideal values and production line stoppages were evaluated in terms of values before and after the improvement.  

Anahtar Kelimeler

• Total Productive Maintenance (TPM),Six Big Losses

Bir Üretim Hattında Toplam Ekipman Etkinliğinin Ölçülmesi Ve Geliştirilmesi Üzerine Bir Uygulama

Öz

Toplam verimli bakım çalışmaları yalın üretim felsefesinin önemli bir basamağıdır. Toplam verimli bakım, üretim faaliyetlerinde kullanılan ekipmanların verimliliğini arttırmak ve olası makine hatalarından kaynaklanacak bozuk veya hatalı parçaları önlemek amacıyla yapılan çalışmaların tümü olarak ifade edilebilir. Yalın üretim ve toplam verimli bakım uygulamalarının ölçülmesinde ise Toplam Ekipman Etkinliği kavramı karşımıza çıkmaktadır. Bu kavram işletmelerdeki makine ve ekipmanın ne derece etkin kullanıldığını ölçmemize yardımcı olmaktadır. Bu çalışmada, işletmelerde verimlilik açısından Toplam Verimli Bakım’a değinilmiş, Toplam Ekipman Etkinliği’nin işletmeler açısından önemi açıklanmış ve bir makarna üretim tesisindeki üretim hattının Toplam Ekipman Etkinliği değerleri hesaplanmıştır. Bu hesaplama sonucunda makine duruş sürelerinin yeteri kadar düşük olmadığı tespit edilmiş ve bazı iyileştirmeler yapılmıştır. Son bölümde ise, Toplam Ekipman Etkinliği değerlerinin ideal değerlerle karşılaştırılması yapılmış ve üretim hattı duruş süreleri, iyileştirme öncesi ve sonrası değerlere göre değerlendirilmiştir.

Anahtar Kelimeler

• Toplam Verimli Bakım (TVB),Altı Büyük Kayıp,Toplam Ekipman Etkinliği (TEE)

Kaynakça

1. Ahuja, I.P.S. ve Khamba J.S., (2008), “Total Productive Maintenance: Literature Review and Directions”, International Journal of Quality and Reliability Management, 25(7), s. 709-756.
2. Bamber, C.J., Sharp J.M. ve Hides M.T., (1999), "Factors Affecting Successful Implementation of Total Productive Maintenance", Journal of Quality in Maintenance Engineering, 5(3), s. 162-181.
3. Bayraktar, E., (Ed.) (2007), Üretim ve Hizmet Süreçlerinin Yönetimi, 1. Baskı, Çağlayan Kitabevi, İstanbul.
4. Becker, J.M.J., Borst J. ve Van Der Veen A., (2015), “Improving the Overall Equipment Effectiveness in High-Mix-Low-Volume Manufacturing Environments”, CIRP Annals – Manufacturing Technology, 64, s. 419-422.
5. Blanchard, B.S., (1997), “An Enhanced Approach for Implementing Total Productive Maintenance in the Manufacturing Environment”, Journal of Quality in Maintenance Engineering, 3(2), s. 69-80.
6. Braglia, M., Frosolini M. ve Zammori F., (2009), Francesco, “Overall Equipment Effectiveness of A Manufacturing Line (OEEML): An Integrated Approach To Assess Systems Performance”, Journal of Manufacturing Technology Management, 20(1), s. 8-29.
7. Brah, S. A. ve Chong W.K., (2004), “Relationship Between Total Productive Maintenance and Performance”, International Journal of Production Research, 42(12), s. 2383–2401.
8. Dal, B., Tugwell P. ve Greatbanks R., (2000), “Overall Equipment Effectiveness As A Measure of Operational Improvement - A Practical Analysis”, International Journal of Operations and Production Management, 20(12), s. 1488-1502.

9. Digalwar, Abhijeet K. ve Nayagam, P. V., (2014), “Implementation of Total Productive Maintenance in Manufacturing Industries: A Literature-Based Matedata Analysis”, The IUP Journal of Operations Management, 8(1), s. 39-53.
10. Ericsson, J. (1997), Disruption Analysis-An Important Tool in Lean Production, Department of Production and Materials Engineering, Lund University, Lund.Fore, S. ve Zuze L., (2010), “Improvement of Overall Equipment Effectiveness through Total Productive Maintenance”, World Academy of Science, Engineering and Technology, 61, s. 402-410.
11. Görener, A. (2012), “Toplam Verimli Bakım ve Ekipman Etkinliği: Bir İmalat İşletmesinde Uygulama”, Electronic Journal of Vocational Colleges, 2(1), s. 15-20.
12. Howell, V., (2012), “Total Productive Maintenance: A Strategy for Your Lean Journey”, Ceramic Industry Journal, 162(10), s. 18-23.
13. Jain, A., Bhatti R.ve Singh H., (2014), “Total Productive Maintenance (TPM) Implementation Practice”, International Journal of Lean Six Sigma, 5(3), s. 293-323.
14. Junker, B.H., (2009), “Application Of Overall Equipment Effectiveness To Biopharmaceutical Manufacturing”, BioPharm International, 22(5), s. 40-50.
15. Ljungberg, Õ., (1998), “Measurement Of Overall Equipment Effectiveness As A Basis For TPM Activities”, International Journal of Operations And Production Management, 18(5), s. 495 – 507.
16. Kotze, D. (1993), “Consistency, Accuracy Lead to Maximum OEE Benefits”. TPM Newsletter, 4(2), s. 1-4.
17. Maggard, B.N. ve Rhyne D.M., (1992), “Total Productive Maintenance: A Timely Integration of Production and Maintenance”, Production and Inventory Management Journal, 33(4), s. 6-10.
18. Mwanza, B.G. ve Mbohwa C., (2015), “Design of a Total Productive Maintenance Model for Effective Implementation: Case Study of a Chemical Manufacturing Company”, Procedia Manufacturing, (4), s. 461-470.
19. Park, K. S. ve Han S.W., (2001), “TPM—Total Productive Maintenance: Impact on Competitiveness and a Framework for Successful Implementation”, Human Factors and Ergonomics in Manufacturing, 11(4), s. 321–338.
20. Prabhuswamy, M. S., Ravikumar K.P. ve Nagesh P., (2008), “Total Productive Maintenance (TPM): An Operational Efficiency Tool”, The Icfai University Journal of Science and Technology, 4(3), s. 41-55.
21. Reyes, J.A.G., (2015), “From Measuring Overall Equipment Effectiveness (OEE) to Overall Resource Effectiveness (ORE)”, Journal of Quality in Maintenance Engineering, 21(4), s. 506-527.
22. Reyes, J.A.G., Eldridge S., Barber K.D. ve Meier H.S., (2010), “Overall Equipment Effectiveness (OEE) and Process Capability (PC) Measures A Relationship Analysis”, International Journal of Quality and Reliability Management, 27(1), s. 48-62.
23. Rizzo, K., (2008), “Total Productive Maintenance”, American Printer, 125(9), s. 16-20.
24. Saleem, F., Nisar, S., Khan, M. A., Khan, S. Z. ve Sheikh, M. A. (2017), “Overall Equipment Effectiveness of Tyre Curing Press: A Case Study”, Journal of Quality in Maintenance Engineering, 23(1), s. 39-56.
25. Singh, R., Gohil A.M., Shah B.D. ve Desai S., “Total Productive Maintenance (TPM) Implementation in a Machine Shop: A Case Study”, Procedia Engineering, (51), s. 592-599.
26. Temiz İ., Atasoy E. ve Sucu A., (2012), “Toplam Ekipman Etkinliği ve Bir Uygulama”, Dokuz Eylül Üniversitesi Sosyal Bilimler Enstitüsü Dergisi, 12(4), s. 49-60.Wang, F. K. ve Lee W., (2001), “Learning Curve Analysis in Total Productive Maintenance”, The International Journal of Management Science, Omega 29, s. 491–499.