M. Tech. Industrial Engineering. / Aims to improve the maintenance strategy in order to improve Return on Capital Investment (ROCI) in a Fast Moving Consumable Goods (FMCG) environment.

Rapporten handlar om att sätta upp en plan för implementering av ett mer strukturerat underhållsarbete på Valmet ABs gjuteri i Karlstad. Arbetet görs i kursen examensarbete för högskoleingenjörsexamen i maskinteknik på Karlstads universitet under våren 2014. Valmet har nyligen köpt upp gjuteriet på Lamberget i Karlstad. Där är det ett mycket eftersatt underhåll och finns i nuläget inte någon bra struktur på hur de arbetar med underhåll. Underhållsverksamheten är i behov av att systematiseras och integreras i Valmets övriga underhållsorganisation. Syftet med arbetet är således att utarbeta en plan för att strukturera underhållet på Valmets gjuteri i Karlstad. Arbetet är indelat i tre faser. - Nulägesanalys genom dels intervjuer av underhållspersonal samt kartläggning av utrustning - Skapa en målbild över hur man vill arbeta med underhåll, genom studiebesök hos andra liknande verksamheter, diskussioner med ledningen samt litteraturstudier. - Upprättande av plan för hur man ska ta sig dit. Vilka aktiviteter som skall utföras samt i vilken ordning, där bland annat lämpliga mätetal ska tas fram. Arbetet är baserat på metodiken TPM (total productive maintenance), det handlar dock inte om ett fullständigt införande av TPM utan begränsat till valda delar. Utifrån intervjuer med underhållspersonalen på gjuteriet samt observationsstudier och en kartläggning av maskinparken har en nulägesanalys gjorts. Denna nulägesanalys har visat de problem och utmaningar som finns på underhållsavdelningen på gjuteriet. En målbild över hur man vill arbeta med underhåll på gjuteriet har ritats upp utifrån de studiebesök samt intervjuer med personal i ledningen. Det mest vitala som framkommit i denna fas är hur viktigt ledningens engagemang är för att kunna genomföra ett förändringsarbete, samt hur viktigt det är med en bra kommunikation både mellan de olika avdelningarna, men också inom gruppen. Med hjälp av de två ovanstående faserna samt den teori som bearbetats under projektet har en plan upprättats för ett mer strukturerat underhållsarbete. Planen innefattar 12 punkter som behandlar de aktiviteter som bör implementeras, samt i den turordning de bör implementeras, för att få en bättre struktur på underhållsarbetet på Valmets gjuteri. De två enskilt viktigaste delarna i planen är enligt mig dels att anställa en person som ansvarar för den dagliga driften av underhållet. Samt att implementera underhållssystemet AM-underhåll, så att man kan få en bättre struktur på underhållsarbetet i form av arbetsordrar, mätetal och historik. / The report is about setting up an Implementation plan for a structured maintenance work on Valmet ABs foundry in Karlstad. This work is the final part for the Degree of Bachelor of Science in mechanical engineering and takes place at Karlstad University in the spring of 2014. Valmet has recently bought the foundry at Lamberget in Karlstad. The maintenance work is much neglected and in the current state there is no good structure. The maintenance work is in need of systemization and integration into Valmets other maintenance organization. The purpose of the project is to develop a plan Implementation plan for a structured maintenance work on Valmet ABs foundry in Karlstad. The project is divided into three phases. - Situational analysis through both interviews of maintenance personnel and identifying the current equipment - Create a vision of how they want to work with maintenance through benchmarking against other similar businesses, and literature studies - Establishment of a plan for how to get there. What activities to be performed and in what order The work is based on the methodology TPM (total productive maintenance). However it is not about an implementation of TPM, but limited to certain parts. From interviews with the maintenance staff at the foundry, observational studies and an identification study of the machinery, a situational analysis has been made. This situation analysis has shown the problems and challenges that exist in the maintenance department at the foundry. A vision of how they want to work with maintenance on the foundry has been drawn, based on study visits and interviews with management staff. It is most vital that emerged in this phase is the importance of management commitment to implement a process of change. A good communication both between the different departments and within the group is also vital. Using the two phases above, together with the theory processed during the project, a plan has been established for a more structured maintenance. The plan includes 12 stages that addresses the activities that should be implemented, and in what order, in order to get a better structure on maintenance work at the foundry at Valmet. The two single most important elements of the plan are, in my mind, to hire a person who is responsible for the daily operations of the maintenance work. As well as to implement the maintenance system AM-underhåll, so you can get a better structure to the maintenance work in the form of work orders, metrics and history.

This research was concerned with investigating “the absence of Total Productive Maintenance (TPM)” at a plastic painting plant. TPM is a combination of operations and maintenance activities and is performed by operators under their own authority and is called “autonomous maintenances”. The author has tested the degree of implementation of TPM by using a sevenstep TPM implementation model this highlighted an absence of TPM in the organisation investigated. TPM is a relatively new concept in the South African automotive industry and has not been fully accepted by management as a solution to the maintenance problems in the organisation. Due to a long implementation period and the difficulty in measuring the benefits of the TPM program for the organisation TPM tends not to be implemented by companies. The research studies several maintenance philosophies each with its own advantages and disadvantages. The benefits that arise from the implementation of an effective TPM philosophy were explored. The development of an effective improved model for the implementation of TPM was investigated. Maintenance engineers and managers in any organisation can use this model to implement an effective TPM program. The seven-step TPM implementation model formed the basis for the compilation of a questionnaire. A survey was conducted to determine if an absence of TPM existed in a plastic painting plant. The results from the survey were drawn up and recommendations to further develop a model for the implementation of TPM was put forward.

For a tyre manufacturing company to compete nationally and internationally, the maximum utilization of their equipment is extremely important. Thus, having a maintenance system in place that will ensure this will be essential. In today’s competitive environment, the need to go further than just scheduling maintenance in accordance with manufacturer’s recommendations as a method of improving productivity and product quality was quickly recognized by those companies who were committed to total quality management programmes. The objective of this study was to propose an appropriate strategy for the implementation of Total Productive Maintenance at Continental Tyre South Africa. To achieve this, the current Total Productive Maintenance (TPM) programme, in the steel stock preparation division in affiliated Continental plants in Otrokovice in the Czech Republic and Puchov in the Slovak Republic was evaluated. A comprehensive literature study was performed on Total Productive Maintenance programmes. A questionnaire was designed based on the guidelines in the literature study in order to establish the effectiveness of implemented TPM programmes. The researcher used the random sampling method of selection and distributed the questionnaire to 62 potential respondents via hand-outs from each plant’s respective heads of departments. 56 completed questionnaires were returned and these were processed and analyzed using Microsoft Office Excel 2003, running on the Windows XP suite of computer packages. The opinions of the various respondents were compared with the guidelines provided in the literature survey, in order to identify how to answer two main questions the author wanted to use as part of selecting an appropriate implementation approach for TPM at Continental Tyre South Africa. These were: • How much are the employees involved and empowered to perform their TPM tasks?; and • How effective is the implemented TPM programme? The following were the main recommendations and conclusions: • The experiences gained by plants like Otrokovice and Puchov must be used as a guideline for introduction and implementation; • The employees that will be required to perform the TPM tasks must be properly trained and they should receive the necessary tools to perform their tasks; • It is essential that everyone throughout the entire manufacturing organization is involved from the start in the development, improvement and maintenance of the TPM programme and that the driving force behind it should be a combination of maintenance, production and quality; and • TPM will achieve it’s objectives if: • The equipment effectiveness can be improved; • Autonomous maintenance is achieved; • Planned maintenance is in place; • Staff are trained in relevant maintenance skills; and • Early equipment management can be achieved.

Manufacturing processes should operate at optimal levels in order to remain competitive in current economic environment. The optimal manufacturing performance can be achieved by overall equipment efficiency which is also a measurement for Total Productive Maintenance (TPM). The successful implementation of TPM has been evaluated at Faurecia Interior Systems. The research consisted out of a literature review into the elements and benefits of TPM. A questionnaire was sent to all operator level personnel at Faurecia Interior Systems to establish their views on the implementation level of TPM at the East London site. In conclusion, this research paper has also led to the development of recommendations which should improve TPM at the site.

O aumento da competitividade no mercado tem estimulado uma grande busca por conceitos e técnicas que auxiliem os processos de melhoria do desempenho de sistemas produtivos, sobretudo no que tange a produtividade e qualidade. Neste contexto, o estudo da experiência das indústrias japonesas revela que a sua competitividade foi conquistada e tem sido sustentada com base em modelos integrados voltados ao planejamento, implementação e condução dos chamados programas de melhoria da produtividade e qualidade (PMPQ\'s). Tais modelos são baseados em filosofias especificas de gestão da manufatura, sendo que os três seguintes, despontam com grande destaque e constituem o objeto central de estudo desta dissertação: 1. Manufatura Just-in-Time (JIT); 2. Total Quality Control (TQC); 3. Total Productive Maintenance (TPM). O presente trabalho é dedicado ao estudo conceitual destes modelos. Para isso foi elaborado um quadro conceitual sobre a estrutura geral de um PMPQ. Tomando-se este quadro como pano de fundo, estes três modelos foram então caracterizados, analisados e avaliados de forma comparativa. Esta análise possibilitou a identificação dos aspectos específicos a cada um, más também evidenciou muitas semelhanças (exemplo: sua aplicação como instrumento de gestão estratégica da manufatura) entre os mesmos. / Along the last decades a series of geopolitical and macroeconomic changes have made the competition in international trade tougher. Although the brazilian economy has not been so integrated to the international market, effects of such trend are already disturbing the dynamics of Braazilian companies. Therefore an increasing number of companies have driven themselves into processes aimed to increase competitive power through strategies that value mainly attributes like cost and quality. Such processes have in general a broad scope and are usully called Productivity and Quality Improvement Programs (PQIP\'s). In this context, new paradigms for planning, implementation and guidance of such programs have risen from japanese industries. Among these paradigms, three of them are worthy of special attention and represent the main object of this work. Each of these paradigms have their own manufacturing management philosophy and are the following; 1. the paradigm based on Just-In-Time (JIT) Manufacturing philosophy, 2. the paradigm based on Total Quality Control (TQC) philosophy and 3. the paradigm based on Total Productive Maintenance (TPM) philosophy, This work is dedicated to the conceptual investigation of these paradigms. First, a conceptual framework for the general structure of a PQIP was built. Then it was taken as a frame in order to present, analyse and evaluate comparatively the three paradigms. The investigation resulted in the recognition of features that are unique to each one but it also exposed many similarities among them. One commom feature is that all three admit their use as a tool for strategic management of manufacturing, an activity that has been overlooked by western industrial companies organized and managed in traditional way. The investigation also revealed a clear resolution of these paradigms to search the achievement of economic objectives of a firm without confronting and neglecting the social and humanistic demands expressed by the human resources engaged in production.

<p><strong><p>Purpose</p>– The purpose of this paper is to review the literatures on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices initiated in a ‘connecter’ manufacturer in China. It also examines the need to develop, practice and implement such maintenance campaign, which not only reduce unscheduled and scheduled failures in process but also decrease operation and maintenance costs. <strong><p>Design/methodology/approach</p>– A case-based approach in combination with scientific theory and standard tools, techniques and practices is used to discuss various issues related with TPM implementation in industry. <strong><p>Findings</p>– The findings indicate that TPM not only leads to increase in efficiency and effectiveness of manufacturing equipments measured in terms of OEE index by reducing the failure, time loss, and defects but also helps organization to improve morale of people and working environment significantly. The contributions of strategic TPM programs towards improving manufacturing competencies of the organizations have also been highlighted here. <strong><p>Originality/value</p>– The paper contains a comprehensive literature on the field of equipment maintenance and also presents an interesting investigation of TPM implementation issues which may be useful to researchers, maintenance professionals and other practitioners concerned with maintenance to understand the significance of TPM. </strong></strong></strong></strong></p>

<p><em>Purpose</em>: this thesis study aims to provide an analysis and an assessment of the current operations’ performance effectiveness at Nobel Biocare’s production plant in Karlskoga, Sweden and to describe the potential for improvement. It intends to clarify the importance of performance measurement and explain Overall Equipment Effectiveness (OEE) metrics in particular.Furthermore, it strives to identify causes for inefficiency in production and suggest recommendations to minimize losses.</p><p><em>Methodology:</em> the study is using both qualitative and quantitative approaches in parallel as measurements are implemented to discover effectiveness rates and detect causes for production losses while assessments are made using different models, such as the Capability Maturity Model(CMM) and OEE assessments, in order to evaluate the current development level and the potential for improvement.</p><p><em>Findings:</em> the research finds that major losses are closely related to frequency of changeovers in machining processes, where average effectiveness rates were 68%. In surface treatment and packaging equipment inspected, the values were found to be between 46% and 59% as the major common cause was the absence of work due to unstable flow of orders. Assessing process orientation and maturity levels, the findings indicate on high levels in general. However, areas of weakness were identified in the different processes in which the potential for improvement is embedded. In those areas, lower OEE values were registered; low levels of maturity and process orientation were found, as low development of losses improvement were assessed. The study finally suggests that the areas of weakness suffer from lack of learning orientation that is ought to be improved and at the same time, a variety of specific recommendations are provided.</p>

<p>Purpose:this thesis study aims to provide an analysis and an assessment of the current operations’ performance effectiveness at Nobel Biocare’s production plant in Karlskoga, Sweden and to describe the potential for improvement. It intends to clarify the importance of performance measurement and explain Overall Equipment Effectiveness (OEE) metrics in particular. Furthermore, it strives to identify causes for inefficiency in production and suggest recommendations to minimize losses.</p><p>Methodology: the study is using both qualitative and quantitative approaches in parallel as measurements are implemented to discover effectiveness rates and detect causes for production losses while assessments are made using different models, such as the Capability Maturity Model(CMM) and OEE assessments, in order to evaluate the current development level and the potential for improvement.</p><p>Findings: the research finds that major losses are closely related to frequency of changeovers in machining processes, where average effectiveness rates were 68%. In surface treatment and packaging equipment inspected, the values were found to be between 46% and 59% as the major common cause was the absence of work due to unstable flow of orders. Assessing process orientation and maturity levels, the findings indicate on high levels in general. However, areas of weakness were identified in the different processes in which the potential for improvement is embedded. In those areas, lower OEE values were registered; low levels of maturity and process orientation were found, as low development of losses improvement were assessed. The study finally suggests that the areas of weakness suffer from lack of learning orientation that is ought to be improved and at the same time, a variety of specific recommendations are provided.</p>

Purpose – The purpose of this paper is to review the literatures on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices initiated in a ‘connecter’ manufacturer in China. It also examines the need to develop, practice and implement such maintenance campaign, which not only reduce unscheduled and scheduled failures in process but also decrease operation and maintenance costs. Design/methodology/approach – A case-based approach in combination with scientific theory and standard tools, techniques and practices is used to discuss various issues related with TPM implementation in industry. Findings – The findings indicate that TPM not only leads to increase in efficiency and effectiveness of manufacturing equipments measured in terms of OEE index by reducing the failure, time loss, and defects but also helps organization to improve morale of people and working environment significantly. The contributions of strategic TPM programs towards improving manufacturing competencies of the organizations have also been highlighted here. Originality/value – The paper contains a comprehensive literature on the field of equipment maintenance and also presents an interesting investigation of TPM implementation issues which may be useful to researchers, maintenance professionals and other practitioners concerned with maintenance to understand the significance of TPM.