Cotton Textile Industry Essay

APPLICATION OF TPM TO ENHANCE OEE IN YARN MANUFACTURING

ABSTRACT In an emergent country like India, the Cotton Textile Industry is exceptionally important, for it has to meet up the demand for clothes of the Indians and exports towards other countries around the world. The Cotton Textile Industry accounts nearly 30% of the total value of exports, and employs more than 55 million labors. In order to withstand the global competition it is necessary to produce higher productivity. Productivity can be ensured by availability of machines without any break downs. The main goal of Total Productive Maintenance(TPM) is to improve Overall Equipment Effectiveness(OEE).The problem faced by the textile industry is six big losses due to the

Breakdown losses
2. Setup and adjustment losses
3. Idling and minor stoppage losses
4. Speed losses
5. Quality defects and reworks losses
6. Yield losses
Pillars of TPM
The basic practices of TPM are often called the pillars or elements of TPM. The entire edifice of TPM is built and stands, on eight pillars. The detailed maintenance and organizational improvement initiatives and activities associated with the respective TPM pillars are as follows: Pillar I - 5S
5S is a systematic process of housekeeping to achieve a serene environment in the workplace involving the employees with a commitment to sincerely implement and practice housekeeping. Problems cannot be clearly seen when the workplace is unorganized. Cleaning and organizing the workplace helps the team to uncover problems.
Pillar II - JISHU HOZEN (Autonomous Maintenance)
This pillar is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value-added activity and technical repairs. The operators are responsible for the upkeep of their equipment to prevent it from deteriorating.
Pillar III - Kaizen

Pillar IV - Planned

This breaks maintenance down into four groups, e.g., breakdown maintenance, preventive maintenance, corrective maintenance, and maintenance prevention. With Planned Maintenance, we evolve our efforts from a reactive to a proactive method and use trained maintenance staff to help train the operators to better maintain their equipment. Pillar V - Quality Maintenance
It is intended to eliminate non-conformances in a efficient way. Quality maintenance aim to achieving zero defects, track and address equipment struggle and root causes as fit as setting 3M (man/machine/material) conditions. It is also aimed towards customer delight through highest quality through defect free manufacturing. The focus is on eliminating non-conformances in a efficient manner, much like a focused improvement. We gain an understanding of what parts of the equipment affect product quality and begin to eliminate current quality concerns, and then move to potential quality concerns.
Pillar VI -