Total Productive Maintenance Assessment on Discrete Manufacturing System

This project focuses on improvement and improvisation of a manufacturing line by using
Total Productive Maintenance concept as tools to help reduce the amount oflosses due to
machine breakdown and other blockage during production. The main objective of this
project is to reduce the frequency of breakdown in order to avoid losses to scrap and also
to increase internal supply chain performance in a given four month period. The
methodology of this project consists of visual observation of the actual production line
and at the same time doing the time study to help find out the waiting time for any
bottleneck point and variability effect.. Manufacturing simulation software WITNESS
also has been used in order to find the number ofthroughput in a controlled condition and
shortest time possible. From that three models were developed to ensure every parameter
is considered before taken into the real operation. Input data for the simulation is attained
from real data from copper wire factory. Model 1 is generated based on reliability
analysis, model 2 is focused on queuing theory and waiting time and model 3 is based on
buffer flexibility. The model is generated to target time of four month time using
WITNESS software.. The breakdown problem in model 1 has been reduced from 40
breakdowns per month to 25 breakdowns per month which is about 37.5% reductions.
The total throughput from model 2 yield 16800 kg of copper wire compared to normal
model which yield 8400 kg in a basis of four month. Model 2 is preferable to be use in
real production base on highest throughput yielding and considerable amount of
breakdown per month.