Implementation of Total Productive Maintenance (TPM) to Improve Overall Equipment Effectiveness (OEE) - Case Study

Modern companies are operating under economic conditions resulting from the global crisis. This situation forces organizations to constantly look for solutions to increase the efficiency, productivity, and flexibility of processes, including manufacturing. In practice, this means implementing solutions based on the Lean Management philosophy. These solutions aim to eliminate waste in various spheres and areas of business operations. Concerning manufacturing companies and manufacturing processes, wastage includes overproduction, underproduction, downtime, machine breakdowns, maintaining unnecessary inventory, or prolonged search for tools and materials. This article aims to analyze the causes of low OEE indicator and its improvement based on a new model of maintenance and overhaul of the machinery fleet in the example of an automotive manufacturing company. Based on the analysis, observations, and interviews with employees documented: the calculation of production capacity calculation of the number of correctly produced strips in the period before the introduction of the new plan for maintenance and overhaul of the equipment used on the KP production line, calculation of the OEE indicator for the entire production process on the KP line, creation of a list of failures occurring at the building and vulcanizing stations, as stations constituting a bottleneck in the production process, calculation of the OEE indicator for machines at the building and vulcanizing stations, categorization of machines and creation of a new model for maintenance and overhaul of the equipment used on the KP production line.