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The initiation of Total Productive Maintenance to a pilot production line in the German automobile industry
2009 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

At WITTE Automotive’s plant in Velbert, Germany, an effort has been started to implement Total Productive Maintenance. It is a Production management method and WITTE’s ultimate goal in introducing TPM is as a means to achieve a leaner production and a calming of the material flow. In Total Productive Maintenance, reliability and availability are the ultimate goals and the way to accomplish the goals is through elimination of the major losses. These losses are only due to mechanical nature and visualised by the key figure Overall Equipment Effectiveness. The goal of the thesis is to achieve an increase in produced units per hour and employee from 140 to 160. In doing so, OEE should also increase, but any gains in productivity or effectiveness should only be justified through measures in TPM, not harder labour. Through literature studies, a workshop with an experienced consultant and a visit at the exemplary TPM implementing company ArcelorMittal in Bremen, the tasks to be performed were set. In order to visualise production losses, a sheet for recording production progress in a timely manner was developed, together with a computer aided analysis, and the possibility to illustrate the data for further evaluation. Meanwhile, the introduction of a task force called TPM-Commando, specialised in eliminating the major losses was to be supported and rendered a continuous improvement process to be applied. Lastly, the author was to provide scheduling and visual aids for introducing the workers to autonomous maintenance. The start value for the thesis goals proved to be overestimated, with the actual initial value at 115 produced units per hour and employee. If the same improvement rate of 14% was to be applied to the new value, the new goal was to top 130 pu/hEE. However, the expectations were surpassed and a value of over 140 was averaged in a four week period, signifying an increase in over 20%. The most significant result however, is the fact that the trend is increasing, as well as the fact that employees found the method to be beneficial to both the company and the operators. Consequently, recommendations were made to fortify the project TPM with a project plan complete with goals and a timeline, as well as to assign sufficient resources to the implementation.

Place, publisher, year, edition, pages
Keyword [en]
Social Behaviour Law, TPM, Total Productive Maintenance, Lean, produktionssystem, production systems, maintenance, underhåll, självständigt, underhåll, autonomous maintenance
Keyword [sv]
Samhälls-, beteendevetenskap, juridik
URN: urn:nbn:se:ltu:diva-54445ISRN: LTU-EX--09/166--SELocal ID: b63d4ac2-d76b-4a76-8a0d-59e87a231acbOAI: diva2:1027826
Subject / course
Student thesis, at least 30 credits
Educational program
Industrial and Management Engineering, master's level
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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