Implementing TPM supported by 5S to improve the availability of an automotive production line

The maintenance management is a topic of strategic importance for automotive manufacturers. In fact, an effective maintenance process and a preventive maintenance (PM) procedure can significantly reduce the risk of equipment failures that can lead to downtime on the production lines. However, due to the complexity of an automotive production system, the risk of failure on a crucial piece of the production equipment cannot be entirely avoided. The study made in this paper aims at improving the availability of a critical production line through the total productive maintenance (TPM) methodology and supported by Lean Maintenance tools. An analysis is made of the initial condition of the line where the main problems are identified by employing several tools for this purpose, such as Mean Time between Failures (MTBF), Mean Time to Repair (MTTR), Overall Equipment Efficiency (OEE) and Availability (A). In response to the identified problems, an action plan is developed and implemented in order to find the root cause of the high number of malfunctions and faults in one of the line’s equipment with the use of 5S tools, visual management, and maintenance progress, as well as the development of a training program to increase operators’ skills. The results of such actions were positive as the line became more organized, the value of the MTBF increased, the MTTR value decreased, and consequently the overall availability increased.info:eu-repo/semantics/publishedVersio

Melhoria da disponibilidade de uma linha de produção através da metodologia TPM

O presente projeto foi desenvolvido na Renault Cacia e teve como objetivo a melhoria da disponibilidade de uma linha de produção crítica através da metodologia TPM e apoiada por ferramentas do Lean Maintenance. Para tal, foi realizada uma análise à situação inicial da linha onde foram identificados os principais problemas. Em resposta aos problemas encontrados foi desenvolvido e implementado um plano de ações: utilização da ferramenta dos 5 porquês de modo a encontrar a causa raiz do número elevado de avarias num dos equipamentos da linha, a revisão do Plano de Manutenção Autónoma (PMA), a reorganização dos armários dos óleos e das peças de desgaste com a utilização dos 5S e da gestão visual, a animação do desempenho e do progresso da manutenção, assim como o desenvolvimento de um programa de formação para o aumento de competências dos operadores. Os resultados destas ações foram positivos uma vez que a linha ficou mais organizada, os operadores começaram a perceber que são fundamentais para o sucesso da linha de produção, o valor do MTBF aumentou, o valor do MTTR diminuiu e, consequentemente, a disponibilidade aumentou.This project was developed at Renault Cacia and it had the objective of improving the availability of a critical production line through TPM methodology and Lean Maintenance tools. For this reason, an analysis was made of the initial state of the line in which the main problems were identified. In response to the problems found an action plan was developed and implemented, in which was proposed the use of the 5 whys tool in order to find the root cause of the high number of faults in one of the line equipment, the revision of the Autonomous Maintenance Plan, the reorganization of the oil and machine parts cabinets with 5S and visual management, creation of a maintenance support dashboard and development of a training program to increase operator skills. The results of these actions ended to be quite positive. The line became more organized, operators began to realize that they are a key for the success of the production line, the value of MTBF increased, MTTR value decreased and thus, consequently, the availability increased.Mestrado em Engenharia e Gestão Industria