Applying Total Productive Maintenance in Aluminium Conductor Stranding Process

Abstract

The purpose of this paper is to apply a total productive maintenance (TPM)technique for increasing the effectiveness in producing aluminium strandedconductors in order to reduce waste problems of the machine and improve thequality of the production. Two pillars of TPM activities for autonomous main-tenance and focused improvement are established. Machines that have lowoverall equipment efficiency (OEE) are chosen as prototype machines. Train-ing program for employees about the production work, cleaning activities todiscover abnormal conditions, corrective actions during abnormal operationsand a one point lesson (OPL) to educate operators for the production processare implemented.Autonomous maintenance standards are also created. Paretoanalysis is used to quickly determine the critical equipment in the factory. Acorrective action team is selected for improving the operation of the process.The research is evaluated by comparing the OEE of prototype machinesbased on production problems occurred before and after the improvement.The results show that the TPM implementation reduces the downtime from7,730.80 minutes per month to 4,942.20 minutes per month, the loss of thescrap from 4,570.00 kilograms per month to 2,236.67 kilograms per month.The OEE is increased from 67.21 percent to 72.14 percent.