A New Manufacturing Improvement Model Based on Overall Equipment Effectiveness and Lean Maintenance

Abstract

This paper proposes a new model for manufacturing effectiveness measurement and improvement basing on the TPM principles and lean maintenance improvement actions. Its methodology is founded on four main pillars. The first one deals with the maintenance process mapping. This part recaps our previous published research on maintenance activities. The second pillar, the main Total Productive Maintenance (TPM) indicator Overall Equipment Effectiveness (OEE) is developed to include other parameters. The third part presents the core of this methodology. In this phase, principal wastes are considered and related to both lean tools and improvement actions. The last pillar concerns an industrial application of the proposed model. The paper presents two major contributions: designing a practical tool to understand the impact of improvement actions on industrial system's effectiveness and proposing a set of unavoidable actions and methods which adhere to their relative impact on the OEE rate. The proposed approach suggests to small organizations a new way to implement Lean methodology faster than usual by using directly appropriate tools to identify and kill waste sources. Further research could improve the proposed tool and thus reach a proposed study with other industrial application.