An integrated approach of maintenance tools and techniques to improve manufacturing performance
In todays competitive markets with increasing demands on manufacturersto produce quality products to tight deadlines, the availability ofmanufacturing plant and equipment is of prime importance.Traditionally, maintenance has often been considered as a second linefunction and non-productive. However, an effective maintenanceactivity can contribute to plant availability and reliability leadingto increased production efficiency and consequently to companyprofitability.This Thesis is concerned with adopting an integrated approach toimplementing maintenance tools and techniques and describes thedefinition, implementation and consolidation of these within atraditional factory environment in order to increase manufacturingperformance.The tools and techniques implemented include re-organisation of themaintenance department to adopt a customer focused team basedapproach, preventive maintenance improvements, implementation ofvarious condition monitoring techniques including vibration analysis,oil monitoring, thermography and the introduction of in-housemonitoring methods as well as the introduction of a computerisedmaintenance management system.As a result of implementing these tools and techniques the company hasseen dramatic improvements. These improvements have realised savingsin excess of £ 220,000 with opportunity costs in excess of£ 1,500,000. Condition monitoring tools allowed the company to meet a50% increase in production during 1995, with an effect on pre-taxprofit in the region of 50%.The results obtained emphasise the importance of an effectivemaintenance strategy to the manufacturing operation. As well as thisits importance to the business as a whole, making it a key businessactivity.
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