Total Cost Effective Maintenance
In modern-day manufacturing, companies thrive to deliver high-quality products in short lead times with fewer costs involved in manufacturing. Due to the current global competition and increasing demand, need for manufacturing performance improvement is high. Due to the increase in automation over the years, the usage of cutting-edge manufacturing technologies and the high investment tied up in production equipment, the significance of asset and maintenance management within manufacturing is continuously expanding.
The aim of Total Productive Maintenance (TPM) is to increase the Overall Equipment Effectiveness (OEE) and to reduce the unplanned machine breakdowns while improving productivity and quality of products. Total Productive Maintenance
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o New maintenance strategies are to be developed for the critical equipment to reduce the corrective maintenance.
The work routines of the maintenance department will be analysed, and more reliable and efficient methods would be suggested. Preventive Maintenance activities must be scheduled to increase the performance of maintenance management. Machine repair process must be optimised such that problems are documented with root causes and measures taken, as this would save time in rectifying errors in similar future breakdowns. Then to continuously improve upon the changes made through new maintenance strategies.
This thesis concentrates on improving the technical availability of the assembly line, thereby reducing the number of reject parts and increasing the availability of the machines. It also strives to improve the effective utilization of the equipment and maintenance resources. It plans to increase the customer satisfaction by improving quality and eliminating complaints regarding assembly. It also tries to reduce the time and costs involved in the secondary analysis of quality
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Data collection can be categorised into Primary and Secondary data. Primary data is the “data that are collected for a specific research problem at hand, using procedures that fit the research problem best.” Secondary data as the “data originally collected for a different purpose and reused for another research question”. Primary data was collected through the literature review on various articles, journals, and books relevant to the following topics. Secondary data was collected through interviews and company documents.
1.5 Thesis Outline
This thesis is structured into six parts. The first chapter gives an introduction and elucidates the background of this project. It also describes the problem and the objectives of this thesis are defined. Objectives are set in accordance with the production manager and maintenance department. The current state of the assembly line is explained under problem description.
The second chapter gives an insight into the company. It describes the KOSTAL Group and about the products manufactured by the company. The product assembled in this assembly line is described briefly. Production process flow of the product is shown with process
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