Study On OEE Improvement Of P Company's Motor Production Line Base On TPM

With the rapid development of China's manufacturing,now the market competition is fierce.Every company has sought advanced lean production methods to improve production and to enhance competitiveness.Among all of the industries,the air-conditioning is the most competitive industry,which is one of the most competitive representative industries.The characteristics of this industry are complicated processes,large amount of high-precision and concentrated equipment.Thus,improving the Overall Equipment Efficiency-OEE is an essential factor of this industry to increase their competitiveness.Company P is a large-scale manufacturing company produces air-conditioning compressors.The factory was established for decades with a well-known brand.Yet nowadays,the low OEE problem makes higher cost and reduces competitiveness.This paper solved the OEE problem of an inverter production line equipment of motor workshop under the P Company's roof,and as a case study to carry out the application research of TPM management measures.Firstly,through the application of mind maps,production surveys and 80/20 principle analysis,the core problems that affecting the OEE were found: machine changeover time,short downtime,failure time,cleaning and inspection time,defect rework time.Subsequently,apply root cause analysis of each core issue for digging out the significant factors and define correspondent measures by applying various tools such as Pareto chart.Afterwards,according to the significant factors and the correspondent root causes,by utilizing “Single Minute Exchange Die-SMED” from TPM individual improvement pillar to solve the problem of long changeover time of winding machines;By applying "PM analysis" tool to solve the problem of the long downtime of the wire binding machine.The "total inspection" method from maintenance planning pillar of TPM is applied the to solve the problem of equipment deterioration.TPM independent maintenance pillar contributes the "repeating group" method to solve the problem of difficult cleaning and inspection operations.Finally,the "8-word deployment" method from TPM quality maintenance pillar has solved the problem of wire damage of insertion machine.The method analysis and application research have effectively solved the core problems that affect OEE of the frequency conversion production line equipment of the motor workshop.The study also summarized various standardized document for best practice sharing.Through this research,OEE of this inverter production line equipment of the company P's motor workshop has increased from 79% to 87.5%,achieved the advanced level of compressor industry,which is also reducing the labor cost and energy consumption of company P approximately 1,820,000 RMB/year.At the same time,the application of various analysis and implementing measures in this research has also formed a strong TPM culture in P Company,which has accumulated valuable experience for the comprehensive improvement of the OEE of all workshops.Moreover,provides lesson learnt experience for similar equipment-dependent enterprises to deploy OEE improvement activities.