Improvement of Overall Equipment Effectiveness (OEE) through Implementation of Autonomous Maintenance in Crankcase Line

Abstract

A study on Autonomous Maintenance (AM) implementation was conducted for CNC machine at automotive components manufacturing line in order to identify and measure equipment losses related to availability, performance and quality rate. These values were used to determine the overall equipment effectiveness (OEE) of the manufacturing line before and after AM implementation. The project started with AM team formation before it was continued with 5S activities and fuguai (abnormality) detection and restoration. Kaizen was used for continuous improvement to restore deteriorated parts and components of the machine. Autonomous Maintenance standards such as cleaning, lubricating and inspection were developed. The AM team members consistently followed the operator maintenance standards to ensure that machine is always in good working condition. The OEE results were taken daily after AM implementation and compared with the data before the implementation. The average OEE result shows significant improvement from 65.8% to 80.4% after the AM implementation. However, the result still did not achieve the company’s target. The main reason was because the machine was very old, which almost reaches deterioration stage according to the bath tub curve. Some recommendations are suggested as to push the OEE value closer to the company’s target including a review on other pillars in Total Productive Maintenance (TPM).

Autonomous maintenance preparation system design with axioms

“…The preparation of standards by operators is strongly recommended by early Japanese sources (Gotoh and Tajiri, 1999). This is confirmed by some literature (Workineh and Iyengar, 2014; Musa et al. , 2015; Joochim and Meekaew, 2016; Musman and Ahmad, 2018; Braglia et al.…”

“…, 2015; Joochim and Meekaew, 2016; Lima, 2019). The latter trainings are 5S (with actual practice) (Jasiulewicz-Kaczmarek, 2014; Workineh and Iyengar, 2014; Musa et al. , 2015; Morales Méndez and Rodriguez, 2017); RCA (Min et al.…”

“…, 2015; Morales Méndez and Rodriguez, 2017); RCA (Min et al. , 2011; Morales Méndez and Rodriguez, 2017); “failure modes” (Chen, 2013); problem-solving (Azizi, 2015; Musa et al. , 2015); Pareto and fishbone analysis (Morales Méndez and Rodriguez, 2017).…”

Increasing Overall Equipment Effectiveness in Automotive Company Using DMAIC and FMEA Method

“…Singh et al [9] researched at CNC machining shop, after implementing Total Productive Maintenance (TPM) by realizing TPM Pillars and improved the losses could increase the Overall Equipment Effectiveness by 16%. Musa et al [10] researched at automotive component manufacturing, Crankcase line, after implementing autonomous maintenance pillar and improvement, OEE could increase by 14.6%. Guariente et al [11] researched at automotive industry, air conditioning tubes manufacturer, after implementing TPM pillars such as: autonomous maintenance, preventive maintenance and improvement, it could increase the availability value by 10% and OEE value by 8%.…”

Improving the Overall Equipment Effectiveness (OEE) of Drum Testing Machine in Laboratory of Tire Manufacturing Using FMEA and PFMEA

“…FMEA is one of the Core Tools contained in international standards for the automotive industry such as IATF 16949 and a quality tool that is widely applied in the automotive, aviation, and electronic semiconductor firms to eliminate potential problem even before a product is mass production [8]. in 1949 the proactive approach was developed first implemented by the United States Army in the 1970s.…”