Can Agile Manufacturing be applied to the Services Industry?
Added on 2019-12-17
25 Pages5789 Words226 Views
Business DevelopmentLeadership ManagementData Science and Big DataCalculus and Analysis
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Manufacturing System
Table of ContentsConcept of ‘Total Productive Maintenance’, TPM.......................................................................................3WHAT IS TPM?.........................................................................................................................................3Types of maintenance:............................................................................................................................41.Breakdown maintenance :...........................................................................................................42. Preventive maintenance (1951 ):.....................................................................................................42a. Periodic maintenance (Time based maintenance - TBM) :............................................................42b. Predictive maintenance:....................................................................................................................53. Corrective maintenance ( 1957 ) :....................................................................................................54. Maintenance prevention ( 1960 ):...................................................................................................5TPM - History:..........................................................................................................................................5TPM Targets:...........................................................................................................................................6TPM is most difficult of all lean tools to implement................................................................................6Other TPM Implementation Considerations............................................................................................71) Some thoughts on supporting the maintenance department culture change:................................72) Of the five potential maintenance strategies:.................................................................................8Industrial case studies identify how the fourth industrial revolution can integrate with TPM..................10Industry 4.0 and Total Productive Maintenance....................................................................................10Case Study:............................................................................................................................................10Six Sigma Project:-.....................................................................................................................................13Pareto Graphs Cause and Effect Diagrams Process Failure Mode and Effects Analysis (PFMEA) SIPOC Charts........................................................................................................................................................13Exhibit how these tools can aggregately be utilized to give an organized critical thinking/indicative abilityinside assembling framework....................................................................................................................13Pareto Chart (Manufacturing Example).................................................................................................13PFMEA RPN Value – Calculated in the Excel Template..........................................................................15Occurrence........................................................................................................................................15Detection...........................................................................................................................................15PFMEA Severity Scale............................................................................................................................15PFMEA Occurrence Scale.......................................................................................................................17PFMEA Detection Scale..........................................................................................................................18
With the utilization of modern cases and/or referenced Case Study examine how Lean Manufacturing, Agile Manufacturing and Six Sigma can supplement the organized critical thinking methods recognized to some degree.........................................................................................................................................20LEAN MANUFACTURING........................................................................................................................20Agile MANUFACTURING........................................................................................................................20Philosophy.............................................................................................................................................20Case Study – COMSAT BRASIL LTDA......................................................................................................21IN THE CASE THAT THE CONCEPT OF LEAN MANUFACTURING SHOULD BE APPLICABLE, HOW COULD ITFORMALLY AND STRUCTURALLY BE USED TO THE SERVICES INDUSTRY?..............................................21IS THE CONCEPT OF AGILE MANUFACTURING SUITABLE TO THE SERVICES INDUSTRY?.......................21IN THE CASE THAT THE CONCEPT OF AGILE MANUFACTURING SHOULD BE APPLICABLE, HOW COULD IT FORMALLY AND STRUCTURALLY BE USED TO THE SERVICES INDUSTRY?..........................................22CONCLUSION.........................................................................................................................................22REFERENCES:.........................................................................................................................................24
Concept of ‘Total Productive Maintenance’, TPM.WHAT IS TPM?It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production:•No Breakdowns•No Small Stops or Slow Running•No DefectsIn addition it values a safe working environment:•No AccidentsTPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strongemphasis on empowering operators to help maintain their equipment.The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity. TPM was introduced to achieve the following objectives. The important ones are listed below.•Avoid wastage in a quickly changing economic environment.•Producing goods without reducing product quality.•Reduce cost.
•Produce a low batch quantity at the earliest possible time.•Goods send to the customers must be non defective.Types of maintenance:1.Breakdown maintenance :It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.2. Preventive maintenance (1951 ):It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.2a. Periodic maintenance (Time based maintenance - TBM) :Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.2b. Predictive maintenance:This is a method in which the service life of important part is predicted based on inspection or diagnosis,in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing dataabout deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.3. Corrective maintenance ( 1957 ) :It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability
4. Maintenance prevention ( 1960 ):It indicates the design of a new equipment. Weakness of current machines are sufficiently studied ( on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing ) and are incorporated before commissioning a new equipment.TPM - History:TPM is a innovative Japanese concept. The origin of TPM can be traced back to 1951 when preventive maintenance was introduced in Japan. However the concept of preventive maintenance was taken from USA. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. Preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of Nippondenso, maintenance became a problem as more maintenance personnel were required. So the management decided that the routine maintenance of equipment would be carried out by the operators. ( This is Autonomous maintenance, one of the features of TPM ). Maintenance group took up only essential maintenance works.Thus Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators. The maintenance crew went in the equipment modificationfor improving reliability. The modifications were made or incorporated in new equipment. This lead to maintenance prevention. Thus preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance. The aim of productive maintenancewas to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment.By then Nippon Denso had made quality circles, involving the employees participation. Thus all employees took part in implementing Productive maintenance. Based on these developments Nippondenso was awarded the distinguished plant prize for developing and implementing TPM, by the Japanese Institute of Plant Engineers ( JIPE ). Thus Nippondenso of the Toyota group became the first company to obtain the TPM certification.TPM Targets:Obtain Minimum 80% OPE.Obtain Minimum 90% OEE ( Overall Equipment Effectiveness )Run the machines even during lunch. ( Lunch is for operators and not for machines ! )
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