Intelligent Total Productive Maintenance to Achieve Zero Downtime and Improve Overall Equipment Efficiency in Foundry Industry

Abstract

Catastrophic breakdown in any manufacturing industry creates a huge loss to the industry in terms of production, damage to machines, repair cost and profit of the organization. If the breakdowns are predicted before the occurrence, zero downtime can be sustained and the demand can be achieved as per customer requirement. Similarly, rejection in a plant increases the production cost through raw material, time, power and manpower wastage. The wastage reduction in the plant increase productivity thereby increasing the profit of the plant. Total Productive Maintenance (TPM) is one of the essential operational excellence tools used in industries to utilize the existing resources of a plant in an optimal way. The eight pillars of the TPM approach improve the Overall Equipment Efficiency (OEE) by improving the factors namely, Productivity, Quality, Cost, Delivery, Safety and Morale of a plant newline