Author : Rohit Sharma V.Trikha

Frequent machine breakdowns, low plant availability and increased overtime are a great threat to a manufacturing plant as they increase operating costs of an industry.   The main    aim of this study was to improve overall equipment effectiveness (OEE)  at  a  manufacturing  company through  the   implementation of innovative  maintenance   strategies . A case study approach was used. The paper focuses on improving the maintenance in a piston manufacturing set up using an innovative maintenance regime mix to improve overall equipment effectiveness. Interviews, reviewing documentation and  historical records, direct and participatory observation were used as data collection methods during the research. Reduced demand and   lack of raw materials particularly imported items are adversely affecting the manufacturing operations.  The company had to reset its targets from a higher limit to a very lower one due to lower availability of machines as result of breakdowns as well as lack of raw materials. The price reductions and   uncertainties as  well  as   general   machine  breakdowns   further lowered   production.  Some  recommendations were given. For   instance,  employee  empowerment  in  the company  will  enhance responsibility and authority to improve   and totally eliminate the big losses. If the maintenance department is  to realize its proper function in a progressive, innovative industrial society, then its personnel must be continuously   trained   to meet current needs as well as future requirements. To make the maintenance planning system effective, it is essential to keep track of all the corrective maintenance jobs   and   preventive  maintenance inspections. For  large   processing plants these cannot be handled manually. It was therefore recommended that the company implement CMMS.

 Keywords: Maintenance, Manufacturing, Overall Equipment Effectiveness

Article published in International Journal of Current  Engineering  and Technology, Vol.1,No.1 (Dec. 2011)