MAINTENANCE MANAGEMENT

ASSIGNMENT 1

TOTAL PRODUCTIVE
MAINTENANCE IN
RMG INDUSTRY

Presented by:
ISHIKA MALU (BFT/19/62)
PRAKRITI GORAI (BFT/19/75)
 TOTAL PRODUCTIVE
MAINTENANCE
Total Productive Maintenance (TPM) is a practise that combines
preventive maintenance with total quality management and total
employee involvement. Operations and maintenance team work
together to identify areas in equipment maintenance. In a TPM
implementation operators take ownership of their equipment for
better maintenance and improved productivity. This approach
emphasizes the role of team work, small group activities, and the
participation of all employees to accomplish equipment
improvement objectives. It challenges a sense of joint
responsibility between operators and maintenance workers, not
only to keep the machines running smoothly, but also to extend
and optimize their overall performance.
The principle activities of TPM are organized as ‘pillars’
 TPM PILLARS
TPM starts with 5S.
Problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps
the team to uncover problems. Making problems visible is the first step of improvement.
SEIRI - Sort, SEITON - Organize, SEISO - Shine, SEIKETSU - Standardization, SHITSUKE - Self Discipline

Autonomous Maintenance
Jishu Hozen, which means autonomous or self-maintenance is daily preventive maintenance (cleaning, inspection, lubrication and re-
tightening) performed by the equipment operator. Autonomous maintenance is one of the most important basic building blocks of TPM
program.It promotes development of production operators to be able to take care of small maintenance tasks, such as cleaning, inspecting,
and lubricating their equipment, thus freeing the maintenance associates to spend time on more value-added activities and technical
repairs.

Focused Improvement Pillar (Kobetsu Kaizen)

"Kai" means change, and "Zen" means good (for the better). Basically kaizen is for small improvements, but carried out on a continual
basis and involve all people in the organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no or little
investment. The principle behind is that "a very large number of small improvements are more effective in an organizational
environment than a few improvements of large value. This pillar is aimed at reducing losses in the workplace that affect our efficiencies.
By using a detailed and thorough procedure we eliminate losses in a systematic method using various Kaizen tools.

Planned Maintenance Pillar

The goal of planned maintenance is to have trouble-free machines and equipment that produce defect-free products for total customer
satisfaction
 TPM PILLARS
Quality Maintenance Pillar
Quality Maintenance (QM) targets customer satisfaction through defect free manufacturing of the highest quality products. The
focus is on eliminating non-conformances in a systematic manner.

Training and Education Pillar

TPM requires investing in training and education. Otherwise, it’s impossible to trust each worker with routine maintenance or prevention. For
TPM to work, basic maintenance knowledge about assets used daily is non-negotiable. Besides, when you think about how fast technology
evolves, continuous training is the only way to make sure your technicians are familiar with new equipment and the state-of-the-art of the
industry.

Office TPM Pillar

Taking TPM to the administrative functions is the next logical step in the TPM program so as to have the whole organization speaking from the
same page. As these are supportive functions, making them understand and apply the principles of lean in their own operations makes it easy
for them to provide efficient service to the main value-creating processes. In addition, spreading the initiative into other functions removes the
silo mentality and encourages horizontal cooperation within the workforce.

Safety Health and Environment Pillar

TPM also aims at zero work accidents, zero pollution, and zero burnout. Good maintenance management not only avoids accidents
during maintenance activities but also contributes to every worker’s well-being and safety.
 Availability

OEE The percentage of time that a machine is actually able to

produce parts out of the total time that it should be able to
produce parts . This number includes breakdowns, setups, and
adjustments. The calculation for availability is simply the actual
production time, including set up, out of the planned production
time.

Performance
Performance is in theory very simple. It is the actual achieved run
rate against the ideal run rate for the machine. Often the machine
Overall equipment efficiency is used as an indicator of ideal or optimum run rate may be the figure published by the
how well equipment is used in batch/lot production. The machine manufacturer. However, we all know that the ideal run
overall equipment efficiency is obtained in relation to losses that rate may be affected by the situation of the machine, heat, cold,
product running through etc. Performance takes into account
can impede equipment efficiency. The magnitude of stoppage loss Speed Loss, which includes any factors that cause the process to
is expressed availability, that of performance loss as performance operate at less than the maximum possible speed, when running.
rate, and that of defect loss as quality products rate ratio. The

Quality
product of the three ratios is called “overall equipment efficiency.” The final factor on the overall OEE calculation is quality. This is
OEE is the most effective measure for driving plant improvement. simply a measure of good product divided by the total product
It continuously focuses the plant on the concept of zero-waste+ (for the job, shift, day, week etc). Quality takes into account
Quality Loss, which accounts for produced pieces that do not
meet quality standards, including pieces that require rework. The
remaining time is called Fully Productive Time.
 RESEARCH PAPER 1
This proposed research was conducted at ABC Clothing Ltd
India, whose major products are knitted fabric based garments.
The researcher recorded the current level of performance
efficiency of selected sewing machines in the product line
subsequently after proper implementation of TPM initiative
along with kaizen implementation towards the reduction of
product lead time. To evaluate the performance, the efficiency
was recorded again after the implementation of TPM. In
conclusion we see that the influence of the TPM tool has
significantly increased the sewing machine performance in all
the cases. Because of the TPM tool implementation, the
operator gets additional skills of troubleshooting sewing
machines, basic maintenance and lubrication. Due to this the
operator will not expect help from the maintenance team which
reduces the sewing machine idle time significantly, whereas the
actual maintenance team will be involved in other development
tasks.
 RESEARCH PAPER 2
This research is mainly performed to measure the existing
situation of OEE and then improve it by comparing with world
class standards in a garments industry. OEE of the different
sections were studied, Data was collected with careful
observations in the month of July 2020. It was observed that
OEE in the sewing section was low in comparison with the
world class. A robust Pyramidal Total Productive Maintenance
(TPM) Model was developed for the improvement in overall
performance in this section. During the study, one of the most
noticeable factors was that the lack of technical knowledge
and inexperience of the employees were associated with most
of the vital defects. After deploying the proposed Pyramidal
TPM model, each parameter of OEE has been re-evaluated to
distinguish the scenario of before and after implementation. It
was concluded that the availability in sewing sections improved
from 82% to 84% after five months. After overcoming all of the
challenges mentioned earlier, the new derivative model of TPM
provided the improved outcome which every company
expects.
 RESEARCH PAPER 3
An existing layout of the sewing floor line of an RMG factory of Bangladesh was studied. It was a complex
and complicated layout therefore a new layout was proposed after implementing standard operating
procedure. The first task of implementing kaizen was to train the operator, line supervisor and other relevant
persons about kaizen and other necessary information. The 5s pillar was also applied before implementation
of kaizen. The 5s scores were noted before and after implementation. Same observations were noted for the
performance efficiency after implementation of kaizen. There was a gradual increase in the efficiency and the
5s score went up from 1.83 to 3.17 after TPM implementation.

RESEARCH PAPER 4
Analysis of Overall Equipment
Effectiveness in the Sewing Section of RMG
Factory: A Case-Study
This proposed study was conducted at 6 factories
of the RMG industry based in Gazipur, Bangladesh.
The focus was on sewing lines which were studied
for 5 days and the following data were collected to
calculate OEE: working hour, designed cycle time,
target and output per day, planned and unplanned
breakdown time, idle and minor stoppage, and
defect per hundred units (DHU).
From the analysis of OEE it has been observed that,
performance is the most influential factor, followed
by and finally quality. On the other hand, from the
comparison between world standard and the
calculated values of OEE factors; it has been
observed that, performance has the highest
deviation (16.71%) from the world standard.
To improve OEE it will be a good initiative to
improve performance by reducing performance
related losses. The two big losses under
performance are: a) idling time and minor
stoppage and b) reduced speed. Root-cause
analysis has been conducted on these two
losses and recommendations are provided. The
root cause analysis are performed through
availability (87.14%), performance (78.29%) and
quality (91.15%) are below from world standard.
Performance is the most influential factor for
OEE enhancement and followed by availability
and quality. As the combined effect, only the
performance-quality relation shows the
significant interaction with OEE. Root-cause
analysis reflects the responsible reasons for the
performance loss associated with man,
machine, material, method, and management
system. Along with, the suggested
corresponding remedial actions can be
applicable in avoiding the performance loss
RESEARCH PAPER 5
The study was performed in Bangladesh at East West Industrial Park
Limited. It is explained here how OEE percentage can be increased by
applying kaizen and increasing the number of trained motivated worker for
basic maintenance work along with other related techniques. The sewing
and cutting section are studied by comparing the OEE percentages. The
study reveals some root causes in the system, which hinders efficiency
level. On the basis of this study, some improvement strategies were
presented. Analytical results from the study confirm that the company can
achieve substantial improvement in their existing OEE percentage, if it
implements the proposed techniques in rest of the line also.
 RESEARCH PAPER 6
TOTAL PRODUCTIVE MAINTENANCE IN RMG
SECTOR A CASE: BURLINGTONS LIMITED,
BANGLADESH
In the study the Sewing section was taken for the
Project purpose. There were 4 lines in the Sewing
section. From the production rate of different lines ,
the one with the lowest production rate was chosen.
From where the losses were identified and to
increase OEE, TPM pillar WWBLA is used.
In this research work, it has been found that OEE has
increased to 65% from 59% while a single problem
was considered and analyzed by only one tool of
TPM (WWBLA). Here, it can also be mentioned that
only one cause of the mentioned single problem has
been considered. Thus from this research work it
can be expected that the OEE could be increased to
a very high level by implementing TPM to an
industry.
 CONCLUSION
Total Productive Maintenance (TPM) is used as an established process in which machine operators get trained to
perform simple maintenance and fault-finding. TPM increases productivity, quality and controls costs inventory,
increases safety and morale. With all these benefits of implementing TPM, it becomes significant for companies to
implement TPM in the manufacturing process of their industry.

If TPM is implemented with its true essence in the organization manufacturing process it increases the organizational
finances both at the top and the bottom of the organization. However, eliminating the losses in the organization business
process is considered as the primary essence of TPM, there are two types of losses that it deals with: losses measured
as breakdowns and quality defects and secondly it deals with the setup or change like minor stoppages, as well as
lesser resources utilization. The implementation of TPM largely focuses on both types of losses mentioned above with
the activities that enhance the overall effectiveness of equipment process and plant through inflexible removal of 16
types of losses and improvement of performance. The process of TPM implementation is first started with the
identification and design of activities that eliminated the losses carefully after measuring and evaluating them.

The conclusion of the secondary research suggests that TPM is the best way to increase productivity and efficiency.
 REFERENCES
Research Paper 1:
https://www.researchgate.net/publication/274611736_AN_EVALUATION_OF_TPM_IMPLEMENTATION_IN_CLOT
HING_INDUSTRY_IN_INDIA-A_LEAN_PHILOSOPHY_BASED_APPROACH

Research Paper 2:
https://www.ejers.org/index.php/ejers/article/view/2376
Research 3:
https://ojs.cnr.ncsu.edu/index.php/JTATM/article/view/4780
Research Paper 4:
https://www.kuet.ac.bd/icmiee2020/Technical_and_Keynote_papers/All_Paper/ICMIEE20-146.pdf
Research Paper 5:
http://businessdocbox.com/Human_Resources/100967620-Implementation-of-autonomous-maintenance-
and-kaizen-to-enhance-overall-equipment-efficiency-in-an-apparel-manufacturing-unit.html
Research Paper 6:
https://www.researchgate.net/publication/238197399_Total_Productive_Maintenance_in_RMG_Sector_A_Case
_Burlingtons_Limited_Bangladesh

https://textilestudy365.blogspot.com/2017/05/total-productive-maintenance-tpm.html?m=1
Thank you