Implementation of TPM in cellular manufacture

A fundamental component of world-class manufacturing (WCM) is that of total productive maintenance (TPM), linked to both total quality management (TQM) and the concepts of continuous-flow manufacturing which are embedded in cellular manufacturing. An investigation was conducted in collaboration with a first tier automotive component supplier to determine the overall equipment effectiveness (OEE) of a semi-automated assembly cell. The big losses associated with equipment effectiveness were also identified. The production output of the cell over the observed period was 26 515. This represents 97% good components, 0.33% scrap and 2.67% rework. The number of stoppages recorded was 156, where the 10 most common causes were identified. The OEE was 62% and the six big losses represent 38% loss of the productive time. Based on the findings, it was recommended that a pilot project to be conducted to implement a TPM programme for the cell and expand it further to the other cells in the factory.