Estudo de aumento da performance de lavadoras industriais por meio da implementação de planos de TPM

Abstract

Amidst the growing demand for higher quality at reduced costs in the market, many suppliers are striving to implement lean manufacturing to boost competitiveness. Total Productive Maintenance (TPM), as a lean tool, focuses on optimizing equipment efficiency, particularly through the analysis and enhancement of Overall Equipment Effectiveness (OEE). This study centers on optimizing the operational efficiency of industrial washers in an automotive company by refining a TPM plan. It begins with a comprehensive literature review covering industrial washers, TPM, maintenance, and relevant indicators. Data collection from the machines, considering TPM plans and overall operational conditions, is followed by defining the ideal operating state based on manufacturer documentation and expert insights. The research zeroes in on analyzing failure modes of washers, underscoring their significance in the company’s manufacturing processes. The meticulous selection of the company’s most critical washers is grounded in OEE indicators and their correlation with production line stoppages. The implementation of specific improvements, guided by a Failure Mode and Effect Analysis (FMEA), aims to reduce recurring failures, especially those linked to impurities in baths, filters, and tanks. The study emphasizes the importance of autonomous maintenance and introduces modifications to the heating system and door seals of the washers. Initial results indicate incremental improvements, with anticipations of more pronounced impacts upon the implementation of specific Technical Instructions.