Tierärztliche Praxis

Vol 40, 2020

Experimental Evidence on Enhancing Equipment Effectiveness with the

Implementation of TPM Principles in the Bus Body Building Industry
N Bagath Singh 1*, A Sivakumar 2

1
Department of Mechanical Engineering, Kurinji College of Engineering and Technology,
Manapparai, Tamil Nadu, India.
2
Department of Mechanical Engineering, Kongu Engineering College, Perundurai, Erode,
Tamil Nadu, India.
*
Email: [email protected] [email protected]

Abstract

Accurate production facilities are an essential factor in the success and productivity of
production systems. As a systematic manufacturing technique to optimize equipment reliability
and productivity by wiping out all production failures, Total Productive Maintenance (TPM) has
been recognized. Equipment availability is a priority area in TPM to increase performance over
the life of the equipment. Research experiment proposes a model of fault tracking to improve the
availability and performance of equipment considering machine maintenance in the system. The
primary aim is to reduce time delays while achieving optimum input parameters in order to
optimize the efficiency of the production process. The built model presents and solves a real
issue. As a result, the equipment effectiveness is enhanced to 64 % from 27 %.
Key Words: TPM, Preventive maintenance, OEE, Taguchi design, World class manufacturing

1. Introduction

The government is introducing schemes to enable the faster adoption of hybrid and
electric vehicles by the automotive industry. Four large car manufacturing centers [1] and three
major government programs have been promoted to encourage the production volume viewpoint,
concentrating on technological growth, growing demand, pilot projects and evolving
infrastructure [2]. The bus body building industry is delighted with the primary public and allied
transport manufacturing in India. The sector is demonstrating its capacity for the workforce to
create a lot of opportunities. Almost 500 construction industries and their associated industries
are in operation in the Karur district of Tamil Nadu, India. A massive amount of capital and
resources is being invested in these industries. Karur is a small town in Tamil Nadu, situated on
the longest-running highway (NH) linking the country's northern and southern extremes. It has
brought a lot of wealth to the Karur district, which can be regarded as the central point of Tamil
Nadu, as it is located on the NH road. Karur reflects the industrial spirit of the central region of
Tamil Nadu, which is a major bus body manufacturing hub.

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The principle of Total Productive Maintenance (TPM) aims to eliminate machinery-

related failures to increase the efficiency of production systems. In theory, multiple performance
metrics are used to track and assess the effectiveness of processes. Provide a complete list of
performance metrics for maintenance decisions and state that Overall Equipment Effectiveness
(OEE) has been the performance evaluation measure [3]. The key benefit of OEE, relative to
several other evaluation criteria, is that it integrates three distinct components into a single
controlled variable and can be viewed as an integrated evaluation metrics for output [4]. The
OEE is a method for monitoring and extending this tool with different terms, such as machine
performance, overall plant yield and plant efficiency [5]. The two OEE motivation approaches
are the identification and exclusion of failures within and between process improvement and
benchmarking production facilities [6]. The variation in OEE measurements from week to week
is responsible for the type of uncertainty and this contrasts with the instability described in the
previous analysis [7]. Researchers consider various types of measurement failure during the
production cycle and emphasize the importance of complexity in performance data as well as its
effect on key metrics [8]. The OEE deal is the same as the accumulation of these three kinds of
considerations [9]. The OEE enhancement, but it is not clear how to apply instruments like 5S,
TPM, within the lean methodology pattern [10]. Numerous of the research results describe to
develop OEE using various methodologies through manufacturing industries [11-14], automobile
industries [15-16] and chemical and textile industry [17-18]. The goal of this research is to
improve efficiency in the bus body building industry.
In this study, the OEE standard has been used as a benchmarking of OEE measurement
and development. The OEE calculation requires an analysis of the fluctuations of production
speed and the failure of machinery. Semi-automatic and automatic measurement techniques are
referred to as major measurement techniques, however large investments are needed. As a result,
the performance assessment of measurements of arithmetic uncertainty for OEE calculation and
world class OEE benchmarking in industrial environments would provide a low-cost true state
[19]. Since this investigate reveals, relative to the performance expected for the machine, OEE
can be used as a significant measure to take the actual potential of the machine into account. The
organization is vulnerable to productivity losses when the OEE is poor. The lack of insight
performed by OEE prediction, and perhaps even the literature, finds that. In addition, the
research also addresses system availability and performance issues that affect the outcomes again
in terms of OEE as well as concentrating on developing models for fault tracking prediction.

2. Research Methodology
The industry selected for research implementation is a leading industry in bus body
building. The company has around 175 employees of whom 145 in shop floor. The build buses
are supplied to Tamil Nadu, Karnataka and too many states in India. Industry management
acknowledged that the efficiency of work decreased and then there be a time delay three times
greater than the work achieved in a pre-planned manner. In order to maximize the productivity of
the work and to reduce time delays, researchers are implementing the TPM program. The studies
have been supported by technicians for problem detection and diagnosis to effectively introduce
TPM in the industry. This blended work approach has helped to fully understand the essence of
the work, the operation and common areas of bottlenecks. The welding machine has been used
for OEE calculation, in particular, for conducting research. A total of ten machines were chosen
to perform feasibility studies as part of the research program. For the machines, two shifts per
day with eight hours per shift are planned. In June 2019, the data is explicitly observed in order
to calculate the existing OEE percentage. The OEE proportion of other devices had also been
calculated by the same method of calculation. Identifying the uncertainties of equipment

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efficiency has been very important in production-related positions. OEE is regarded in this
research as an efficiency indicator of equipment. The entire research methodology has been
clarified in figure 1 for a simple understanding of the procedure.

Summarize research Arithmetic measurements

Correlation matrix

No
Implement improvement Satisfaction
strategy level

Yes

Taguchi optimization Benchmark results

Figure 1. Research methodology chart

3. Implementation of Improvement Tools

TPM can be described in terms of overall equipment efficiency from a standard

viewpoint. The TPM's purpose is to optimize production. An easy way to calculate and evaluate
the performance of the system is given by OEE. The system failure category of the TPM system
is classified by availability, reliability and quality. To examine the effectiveness of the device,
the resulting OEE is used. A comprehensive description of the parameters used, the notation,
their units and also the formula is given in the table 1.

Table 1. Research parameters with calculation

S.No Parameter Notation Units Calculation

1 Planned Production Time Tp Minute measurement
2 Planned production Speed Sp weld per minute measurement
3 Planned quantity Pw numbers Tp * Sp
4 Time per weld Tw Second measurement
5 Labour movement Time Tlm minute measurement
6 Unscheduled break down Time Tb Minute measurement

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7 Changeover & adjustment time Tc Minute measurement

8 Scheduled Stoppage Duration Tss Minute measurement
9 Realized Stoppage Duration TLrs Minute Tlm + Tb + Tc + Tss
10 Total Operating Time To Minute Tp - TLrs
11 Realized Production Speed Sr Weld per Minute measurement
12 Defects and rework Lr numbers measurement
13 Total acceptable quantity Toaq numbers Tow - Lr
14 Total quantity of work Tow numbers Sr * To
15 Production Losses due to stoppages PLus Minute TLrs * Sr
16 Production Losses due to Reduced Speed PLs Minute (Sp - Sr ) * Tp

Consider that the availability variable is estimated in terms of time and unplanned stops,
whereas performance is estimated in terms of time and velocity, while the efficiency variable is
estimated in terms of time and quantity. Equations 1-3 also assess availability, efficiency and
quality.
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 (𝐴) = Total Operating Time / Planned Production Time = To / Tp = Tp - TLrs / Tp --------- (1)

𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒(𝑃) = Realized Production Speed / Planned production Speed = Sr / Sp = [(To – (Li + Lm))/

Tw] / Sp ----------- (2)

Quality (Q) = Total acceptable work/ Total quantity of work = Toaq / Tow = Tow - Lr / Sr * To ----------- (3)

Once all the observations remain precise, the OEE facilitates as shown in Equation 4.

𝑂𝐸𝐸 = To / Tp * Sr / Sp * Toaw / Tow -------------(4)

The loss calculation formula described in Equation 5-7 has been used.

𝐴𝑐𝑡𝑢𝑎𝑙 𝑙𝑜𝑠𝑠(𝐿𝐴 ) = Planned quantity - Total acceptable quantity = Pw - Toaq in numbers -----------(5)

Calculated loss (𝐿𝑐 ) = Planned quantity - Total quantity of work = Pw - Tow in numbers ----------- (6)

Unexpected loss (𝐿𝑢 ) = 𝐴𝑐𝑡𝑢𝑎𝑙 𝑙𝑜𝑠𝑠 − Calculated loss = 𝐿𝐴 − 𝐿𝑐 in meters -------------- (7)

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The observations and estimates of the selected parameters described in table 2 and the
calculated OEE results are also described in the same table.

Table 2. Research parameters estimation

S.No Notation Units Estimates S.No Notation Units Estimates

Weld per
1 Tp Minute 395 11 Sr 0.5
Minute
weld per
2 Sp 1.2 12 Tow numbers 135
minute
3 Pw numbers 474 13 Lr numbers 8
4 Tw Second 50 14 Toaq numbers 127
5 Tlm minute 16 15 PLus minute 63
6 Tb Minute 48 16 PLs minute 276
7 Tc Minute 12 17 A percentage 68
8 Tss Minute 50 18 P percentage 42
9 TLrs Minute 126 19 Q percentage 94
10 To Minute 269 20 OEE percentage 27

Structured research indicates that the rejection rate is very low and that the machinery is
in good condition. So, for this machine, consistency is not a problem, while availability and
performance are considered to be inefficient. The calculated OEE score of 27 percent is not a
reasonable value of success compared to the world-class OEE result of 85 percent and the figure
2 proves it.

Estimated value Vs World class value

120
100
Percentage

80
60
40
20
0
A P Q OEE
Estimated value % 68 42 94 27
World class value % 90 95 99 85

Figure 2. Comparison of values estimated with world class

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The overall ten machine’s estimation is shown in figure 3. This means that a scientific
verification study has been conducted to test the unstable parameter.

OEE Estimation for all machines

120

100

80
Percentage

60

40

20

0
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10
A 68 68 68 69 68 68 66 66 67 66
P 42 42 54 63 42 63 54 42 54 42
Q 94 93 93 96 93 95 95 92 94 92
OEE 27 26 34 41 26 40 34 25 34 25

Figure 3: OEE Estimation for all machines

The correlation coefficient analysis utilizes the intensity and direction of a linear
relationship between database variables. The correlation coefficient study uses the intensity and
direction of a linear relationship between database variables. Correlation coefficients are in the
range of -1 and +1. The higher unconditional coefficient values result in a healthier combination
of variables. In this case, it can be seen that the exact value of 1 is the ideal linear relationship
and 0 is the nonlinear relationship between variables in the Pearson correlation system. Table 3
shows that, most of the time, the relation between parameters is determined to be near 1.
Consequently, none of the comparisons are very close and there is no history of over-inference.

̅)
(∑𝑛𝑖=1( xi − x̅)(yi − y)
𝜌= − − − − − (8)
(n − 1)sx sy

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Table 3: Pearson Correlation Matrix

Tlm Tb Tc TLrs To Sr Tow Lr Toaq PLus PLs A P Q OEE

Tlm 1 -0.86 0.46 -0.08 0.08 0.42 0.41 0.62 0.39 0.43 -0.42 0.08 0.42 -0.04 0.39

Tb -0.86 1 -0.17 0.52 0.52 -0.58 -0.60 -0.55 -0.58 -0.50 0.58 -0.52 -0.58 -0.17 -0.58

Tc 0.46 -0.17 1 0.71 -0.71 0.04 -0.02 0.22 -0.03 0.18 -0.04 -0.71 0.04 -0.17 -0.03

TLrs -0.08 0.52 0.71 1 -1.00 -0.39 -0.46 -0.10 -0.46 -0.21 0.39 -1.00 -0.39 -0.34 -0.46

To 0.08 0.52 -0.71 -1.00 1 0.39 0.46 0.10 0.46 0.21 -0.39 1.00 0.39 0.34 0.46

Sr 0.42 -0.58 0.04 -0.39 0.39 1 1.00 0.18 1.00 0.98 -1.00 0.39 1.00 0.75 1.00

Tow 0.41 -0.60 -0.02 -0.46 0.46 1.00 1 0.18 1.00 0.96 -1.00 0.46 1.00 0.75 1.00

Lr 0.62 -0.55 0.22 -0.10 0.10 0.18 0.18 1 0.13 0.16 -0.18 0.10 0.18 -0.51 0.13

Toaq 0.39 -0.58 -0.03 -0.46 0.46 1.00 1.00 0.13 1 0.96 -1.00 0.46 1.00 0.78 1.00

PLus 0.43 -0.50 0.18 -0.21 0.21 0.98 0.96 0.16 0.96 1 -0.98 0.21 0.98 0.73 0.96

PLs -0.42 0.58 -0.04 0.39 -0.39 -1.00 -1.00 -0.18 -1.00 -0.98 1 -0.39 -1.00 -0.75 -1.00

A 0.08 -0.52 -0.71 -1.00 1.00 0.39 0.46 0.10 0.46 0.21 -0.39 1 0.39 0.34 0.46

P 0.42 -0.58 0.04 -0.39 0.39 1.00 1.00 0.18 1.00 0.98 -1.00 0.39 1 0.75 1.00

Q -0.04 -0.17 -0.17 -0.34 0.34 0.75 0.75 -0.51 0.78 0.73 -0.75 0.34 0.75 1 0.78

OEE 0.39 -0.58 -0.03 -0.46 0.46 1.00 1.00 0.13 1.00 0.96 -1.00 0.46 1.00 0.78 1

The association between the uncertainty factor and OEE conditions are analyzed. First
the relationship with OEE is represented “OEE/A/P/Q”. Secondly input parameters correlation
inspected and derived as “A/ To”, “P/ Sr / Tow” , and “Q/ Toaq / Tow”. Further “To/Tb/ Tow/
Toaq”, “Sr / Tow”, “Tow/ Toaq/ Sr” and Toaq / Sr / Tow . Finally by the correlation uncertainties
are identified as “Tb, Tow, Toaq & Sr” as shown in figure 4.

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A To Tb

Sr Tow
OEE P
Tow
Toaq
Q Toaq
Sr
Figure 4. Uncertainty prediction using correlation

It is necessary to analyze the current situation in order to promote countermeasures. The

situation and the causes of production losses observed are described in the figure 5.

Maintenance carried out if problem exits

Poor plant layout

Productivity
Unscheduled breakdown
loss

Low production speed

Total quantity of work produced & accepted

Figure 5. Schematic diagram of current environment

For example, plenty of the difficulties are due to obstruction that can be resolved by the
workers itself by basic maintenance measures, such as cleaning, storing rods and equipment.
This includes the maintenance of proper facilities by following the principles of a Japanese 5'S as
shown in the figure 6.

Store tools near the area of

welding machine

Cleaning the work place free of

Completed parts storage
grease, oil, waste, scrap, burrs
5’S

Punctuality, dedication and work Pathways, manual and charts

procedures testing and inspection

Figure 6. 5’S implementation process

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Preventive maintenance has been encouraged to consistently upgrade the unit. On a

weekly basis, the electrical failure maintenance routine followed power sources to prevent
overheating and irregular arc production by blowing air inside the unit. The cable and electrode
holder would also generate problems such as excessive circuit resistance, so the connections,
circuits, wires, liners, hoses, regulators and inside guns would be inspected regularly. Direct
replacement ones with excess wear immediately. Of course, the coolant level is controlled with
blended coolant from the manufacturer to solve the problem related to sludge build-up.
Concentrate mainly on welding generator engines such as oil shift, filter, air cleaner and fuel
filter. Finally, perform the load test to ensure that the performance of the welding is precise.
With a view to promoting maintenance activities, as shown in the table 4,a fault tracking model
has been built. It consists of a sensitive full record of frequently failing information associated
with relevant specifics such as time and date for fault detection, mean time between failures for
repair.

Table 4. Fault tracking model

S.No Inspection Machine Failure detection Mean repair Mean time between
number date & time time (hours) failures (hours)
1 Power source
2 Cables & holder
3 Circuit
4 Welding gun
5 Coolant
6 Hoses & regulator
7 Welding generator
8 Load test

The estimate of the outcome of the parameters is determined after implementing the
maintenance and management enhancement plan. In the first shift, the efficiency metrics of one
machine are measured for one week and summarized in a table 5.

Table 5. Autonomous maintenance implementing results

S.No Notation Units Estimates S.No Notation Units Estimates

1 Tp Minute Sr Weld per
395 11 1
Minute
2 Sp weld per Tow
1.2 12 numbers 310
minute
3 Pw numbers 474 13 Lr numbers 4
4 Tw Second 50 14 Toaq numbers 306
5 Tlm minute 8 15 PLus minute 85
6 Tb Minute 15 16 PLs minute 79
7 Tc Minute 12 17 A percentage 78
8 Tss Minute 50 18 P percentage 83
9 TLrs Minute 85 19 Q percentage 99
10 To Minute 310 20 OEE percentage 65

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The introduction of TPM principles, the availability is enhanced from 68 to 78 percent,

performance is enhanced from 42 to 83 percentage, quality is from 94 to 98 percent and OEE
percentage have been improved from 27 percent to 64 percent. The parameter estimation shows
that the time of the unplanned breakdown is reduced from 48 to 15 minutes. The production
speed realized is increased from 0.5 to 1 Weld per minute. In addition, the total acceptable
quantity improved from 127 to 306. The total amount of work rose to 310 from 135. The
estimation of input and output parameters for all ten machines is figured out in figure 7.

OEE Estimation for all machines after improvement

120
100
Percentage

80
60
40
20
0
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10
A 78 77 78 76 78 77 78 78 78 78
P 83 79 83 83 83 79 79 79 83 83
Q 99 98 98 98 98 98 98 98 98 98
OEE 65 60 64 63 64 60 60 61 64 64

Figure 7. Estimation of input & output parameters

To determine the system parameters significantly affect output and at what rate, the
Taguchi design method is used. Three variables, such as availability, efficiency and quality rate,
are taken with three degrees of variance. The reference values reported have been drawn from
the deviation in the calculation. 79, 80 & 81 percent availability; 79, 81 & 83 percent
performance; 97, 98 & 99 percent quality score. The reference values varied with a particular
purpose to evaluate results. To perform the Taguchi orthogonal array design L9 (3˄ 3) is
preferred, with three variables and nine runs as well as L9 (3˄ 4) columns of the range of levels
of 1, 2, 3. The Taguchi orthogonal array model output is computed in table 6.

Table 6. Taguchi orthogonal array model

Availability % Performance % Quality rate % OEE %

1 1 1 60.67
1 2 2 64.37
1 3 3 65.03
2 1 2 62.08
2 2 3 65.86
2 3 1 67.58
3 1 3 63.50
3 2 1 65.32
3 3 2 69.14

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The performance of Taguchi design shows that, the minimum value obtained in
performance rate of 76, 79 & 97 % and maximum values obtained in 78, 83 & 98%. The
comparison of Taguchi design values computed in figure 8.

Tagchi Experimental result

100
90
80
Percentage

70
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9
A 76 76 76 77 77 77 78 78 78
B 79 81 83 79 81 83 79 81 83
C 97 98 99 98 99 97 99 97 98
OEE 58 60 62 60 62 62 61 61 63

Figure 8. Taguchi design values comparison

The predicted performance values of Taguchi analysis of OEE, availability, performance

and quality rate is computed in table 7 and main effects graph computed in figure 9 a & b.

Table 7 : Response Table for Signal to Noise Ratios, Means & Predicted Values

Signal to Noise ratio Means

Level
Availability Performance Quality Availability Performance Quality
1 35.61 35.51 35.72 60.34 59.62 60.51
2 35.72 35.72 35.72 61.12 61.12 61.13
3 35.83 35.94 35.81 61.91 62.63 61.73
Delta 0.23 0.43 0.18 1.57 3.01 1.23
Predicted Values
S.No Availability Performance Quality S/N ratio Mean
1 78 83 99 36.1362 64.0283

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Figure 9.a Main Effects Plot for Means Figure 9.b Main Effects Plot for SN ratios

The prediction demonstrates that while parameter values are increased, the S/N ratio and
mean values are increased. The analysis suggests that the OEE would be maximized to 64
percent, thus parameter sequence of 78 percent availability, 83 percent performance & 99
percent quality rates with predicted S/N ratio of 36.1362.

4. Results and Conclusion

The correlation analysis enables to classify the strongly correlated parameters that
significantly influence the performance and those parameters that are known as uncertainty. The
incorporation of 5’S principle, the restructured shop floor improves the healthier environment.
The comparison of the pre-and post-TPM implementation experimental results shows that
availability, performance and quality input parameters are enhanced and OEE output parameters
are augmented from 27 percent to 64 percent. The benchmark of input and output parameters for
world-class OEE results is seen in table 8 and the relation is found in the figure 10. It shows that
the OEE percentages are 64 & 64, the experimental and Taguchi estimation. In order to maintain
the work in a pleasant manner, the optimal values should be used.
Table 8: Benchmark with world class OEE

Experimental OEE %
Particulars Taguchi prediction World class OEE %
Before TPM After TPM
A 68 78 78 90

P 42 83 83 95

Q 94 98 99 99

OEE 27 64 64 85

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Benchmark inputs and OEE

120

100

80
Percentage

A%
60 P%
40 Q%
OEE %
20

0
Before TPM After TPM Taguchi World class
prediction

Figure 10: Benchmark of predicted and world class

Obtained results from the incorporation of TPM indicate not only that the performance of
production equipment has increased, but also benefits have improved massively in other ways,
including such workforce friendly nature through establishing team building and performance
awareness. The research concluded that the machine should meet the challenges of the dynamic
production environment for the machine. The intended outcomes of reducing time delay and
optimizing availability through the incorporation of TPM are accomplished by increasing
operator engagement and process ownership and improving the problem-solving capabilities of
operators, too. Mainly refining the practices of preventive maintenance is achieved. Improving
OEE outcomes is fine, even though it is recommended that some consistency is needed to
achieve world-class results.

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