www.tjprc.org editor@tjprc.org IMPLEMENTATION OF TOTAL PRODUCTIVE MAINTENANCE TO ENHANCE THE OVERALL EQUIPMENT EFFECTIVENESS IN MEDIUM SCALE INDUSTRIES S. NALLUSAMY, VIJAY KUMAR, VIVEK YADAV, UDAY KUMAR PRASAD & S K SUMAN Department of Mechanical Engineering, Dr. M G R Educational and Research Institute, Chennai, Tamilnadu, India ABSTRACT In current globe state, manufacturing companies are in need of sustaining their production level to meet the customer demand. Whenever capacity problem arises, immediately they look for increasing overtime, number of shifts and purchase new machines and equipments. As an alternative, they should focus on the better utilization of resources and increasing performance of the existing machines which leads to an improvement in the equipment performance, reduction in bottlenecks, decrease overall downtime, improve operator performance and minimize setup time and other major forms of losses, thus enabling in decision on the investment of buying new machines. In this research, an attempt was made to implement total productive maintenance to achieve overall equipment effectiveness (OEE) close to world class standards. Result analysis shows that, downtime losses are not the only influencing parameter, but idle time of a machine is another factor that adds to the variation in OEE. It is evident that the percentage OEE can be improved substantially by implementing total productive maintenance lean tools such as Jishu Hozen, Kaizen etc in a manufacturing company. While calculating OEE, the factors influencing it are identified and performance improvement measures are undertaken. From the observed results, it was found that, the percentage OEE can be improved from 55.45% to 68.04% by implementing this technique in medium scale industries. KEYWORDS: Lean, TPM, OEE, Kaizen & Production Rate Received: Dec 22, 2017; Accepted: Jan 12, 2018; Published: Feb 01, 2018; Paper Id.: IJMPERDFEB2018123 INTRODUCTION In present business scenario, every manufacturing company faces increasing competition and hence attempts to be an effective, low-cost producer of their product with high productivity. Many times, attaining higher productivity and bringing their product to the market with minimum cost is not possible due to various factors related to capacity problems and problems related to performance of machines such as machine breakdown, minor stoppages, unplanned maintenance, reduced speeds, quality rejects and rework. In such situation, an investment is made on buying new equipment, increased shifts and increased working hours. This causes business executives to be sensitive about all aspects of manufacturing operational costs. Hence lean tools must be used, as lean entails using less or the minimum of everything required to produce a product or perform a service. Overall equipment effectiveness measures the gap between the actual performance and the potential performance of a manufacturing unit. OEE encompasses three measuring metrics such as availability, performance and quality. These help gauge the plant’s efficiency by categorizing the key losses that affects the manufacturing process. Downtime reductions can be readily achieved by using OEE to gain visibility into machine status and to perform root-cause analysis of problems. Original Article International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249-6890; ISSN (E): 2249-8001 Vol. 8, Issue 1, Feb 2018, 1027-1038 © TJPRC Pvt. Ltd.