Research On Total Productive Maintenance Management Optimization Of ALT Company

Petroleum and chemical industry is an important foundation and mainstay in our country.In recent two years,petroleum and chemistry industry has been facing severe challenges,affected by gloomy world economy,high tension of main source of oil,and enhancing domestic regulation on safety and environment.NBR manufacture,as part of petroleum and chemical industry,is face multiple challenges as well for fierce competition,unpredictable raw material supply and customer demands.ALT(Nantong)Chemical Industrial Co.,Ltd is a chemical joint venture established by Arlan and Taiwan TS groups,who produce NBR by low temperature emulsion polymerization.In this article,Total Productive Maintenance(TPM)management in ALT is selected as research object.Firstly of all,TPM management situation in ALT is presented through information collection,on-site observation and staff interviews.Then,through statistics and analysis on Overall Equipment Effectiveness(OEE),availability loss,performance loss and quality loss,the main problems are confirmed as low performance rate,high failure rate of main equipment and long repair time.Thirdly,by matrix graph and Why-Why tools,the root causes of these problems are unspecific management measures,low quality of self-maintenance,insufficient knowledge on failure mold and regularity,low effective improvement on inherent defects of equipment.At last,taking PDCA as common thread and Three Total,including Total Efficiency,Total System,Total Involvement of Staff,as the main idea,develop systematic solutions aiming at identified problems and root causes,including optimization for TPM objectives,fully application of information management system,enhancing self-maintenance activities,enhancing capability of professional maintenance and establishment of regime for self-improvement team.To support effective implementation of optimization,a specific plan is established based on 5W1 H principle.Meanwhile,Appropriate human resource,adjusted organization structure,optimized TPM management responsibilities and top management commitment are determined as guarantee measures to reach expected objectives for TPM.Not only for traditional manufacturers,but also for intelligent manufacturing enterprises aiming at industry 4.0,Total Productive Maintenance(TPM)will play an important role in their reliability management of equipment.This article is an exploration of how to effectively implement TPM in synthetic rubber production enterprises,which not only plays a positive role in promoting the improvement of the comprehensive efficiency of equipment in enterprises,but also provides reference for other petroleum and chemical enterprises to implement TPM.