MODULE: EEM7020 – Integrated Management Systems

LEVEL HE 7: ASSIGNMENT 1
Title: Total Productive Maintenance & Failure Mode and Effects Analysis (FMEA)

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Table of Contents
Part 1...........................................................................................................................................................3
1.1 Seiichi Nakajima...............................................................................................................................3
1. Focus on Total Participation:...........................................................................................................3
2. Preventive Maintenance:..................................................................................................................3
3. Autonomous Maintenance:..............................................................................................................4
4. Overall Equipment Effectiveness (OEE):........................................................................................4
5. Cultural Transformation:.................................................................................................................4
1: Literature survey and definitions.........................................................................................................4
Total Productive Maintenance (TPM):................................................................................................4
Equipment Availability (Reliability Factor):.......................................................................................4
Process Yield (Quality Factor):...........................................................................................................5
Performance (Speed Factor):...............................................................................................................5
Overall Equipment Effectiveness (OEE):............................................................................................5
2:.............................................................................................................................................................5
(a) Determining OEE and Manufacturing Quality...............................................................................5
(b) Target Benchmark Value for OEE in European Automobile Manufacturing.....................................6
Part 3...........................................................................................................................................................6
3.1 FMEA table.......................................................................................................................................6
References...................................................................................................................................................8

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Part 1

1.1 Seiichi Nakajima

Seiichi Nakajima, a Japanese industrial engineer and the pioneer of Total Productive Maintenance
(TPM), was at the forefront of implementing TPM in his country. Barely representing 30-year life
span, Nakajima is well-known for his operation improvement principle derived through
implementing TPM system (Thakur and Panghal, 2021). TPM represents a more extensive method
of maintaining equipment that helps to improve the utilization of the production equipment
(Braglia, Castellano and Gallo, 2019). Low-selling points of Nakajima's TPM work were the
active participation of all personnel in the maintenance operations. This underlines a proactive
approach to prevent unplanned repairs rather than the reactive approach. He held the opinion that
equipment downtime could be drastically reduced by combining maintenance activities with a
company’s day-to-day operations (Agustiady and Cudney, 2023).

Nakajima's work is characterized by several key features: Nakajima's work is characterized by

several key features:

1. Focus on Total Participation: According to Chaurey et al. (2023), Nakajima underlined the
ability. Therefore, all workers need to be included in the maintenance process. He posited that
maintenance should not be handled by maintenance section alone and that everyone from
directors, to supervisors and operations should be involved. Total participation approach applies a
strong sense of belonging among workers for the environment that also favour the success of their
organization (Hameed et al., 2019).

2. Preventive Maintenance: Nakajima engaged in prevention service by putting in place

predictive measures and ensuring that equipment operates on continuous basis in order to
minimize breakdowns and downtime (Juraev, 2022). Frequent monitoring, cleaning and small
fixes allows to detect and to solve early much more likely the problems than if that promise was
delayed. Alongside this prevention-oriented approach, production processes can be kept operating
in a fuss-free manner (Trehan, Gupta and Handa, 2019).

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3. Autonomous Maintenance: One of the fundamentals of Nakayadatol approach is called
autonomous maintenance, and by empowering workers and operators to have an active role in
their machines technical care (Xiang and Chin, 2021). via trainings and education a shop
employee can learn simple maintenance procedures, such as cleaning, lubricating, and inspecting
the machine (Rizkya et al., 2021).

4. Overall Equipment Effectiveness (OEE): Nakajima came up with Overall Equipment

Effectiveness (OEE) metric as the key performance indicator which depicts the extent to which the
equipment is utilized for the production process. OEE is indicative of the Availability,
Performance, and Quality hence is a thorough assessment tool of the equipment.(Schiraldi and
Varisco, 2020).

5. Cultural Transformation: Nakajima understood that effecting TPM meant a change in the
culture of the enterprise. He stressed that leadership commitment, involvement of the employees
and long term learning are the macadamizing forces in change of culture. Through creating
collaboration, accountability, and constant improvement oriented culture in their organizations,
they can reach better results in productivity and performance (Zlatić, 2019).

Through Nakajima evidence as a base, the principles of TQM incorporate leadership through
continuous improvement, employee involvement, and customer satisfaction. Nakjima's concern on
the concept of preventive maintenance reflects the principles of these two that Total Quality
Management Quality Control and Defect Prevention throws at us (Kadhim and Ahmad, 2021).

1: Literature survey and definitions

Total Productive Maintenance (TPM): TPM is a complex approach of maintenance that
addresses the needs of equipment to support its utmost production efficiency and effectiveness.
Equipping with proactive maintenance practices staff engagement, and constant improvement just
like minimizing downtime, reducing faults and optimizing the OEE is all possible (Pinto et al.,
2020).

Equipment Availability (Reliability Factor): Equipment availability means how workable

machines and systems are, when they are needed for production. Reliability is the nomenclature

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which depicts the proportion of time during which the equipment is in working condition and
available to use, without slowing down or coming to a stop because of breakdowns or other
unplanned shut-downs (Worximity, 2019).

Process Yield (Quality Factor): The process efficiency gauge for a given manufacturing
operation is the percentage of satisfactory products yielded in a given operation. It shows the level
of production by demonstrating the proportion of goods which are free from defects and conform
with quality specifications standard (Precognize, 2023)

Performance (Speed Factor): Speed is the main indicators of performance in the manufacturing
context when productive equipment processes are concerned. It gauges the efficiency of
equipment use based on cycle time, throughput and productivity. It shows the level of equipment
meeting production targets and customers’ demands (Bao et al., 2019).

Overall Equipment Effectiveness (OEE): OEE is an inventory performance indicator intended

for performance and efficiency evaluation of manufacturing machinery. That combines indicators
of availability, performance, and quality to give an overall evaluation of which the equipment
effectiveness arises while there are possibilities for such improvement and optimization in
production processes (Trout, 2019).

2:

(a) Determining OEE and Manufacturing Quality

As per Tsarouhas (2019), the general relationship between consistent overall manufacturing
quality and OEE (overall equipment effectiveness) mostly works. OEE is an all-rounded
equipment measurement reporting to every department, including availability, performance, and
quality (Cheah et al., 2019.). Whether it is spotting idle moments or incompetent processes, OEE
analysis allows for the improvement of efficiency, less of a defects building up and more
available product quality enhancement. This result in predictive maintenance, equipment
longevity and improved operation, all of these lead to superior quality. Therefore, though OEE
applied to production processes might be totally new and requiring of initial adjustments,

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 favorable insights obtained from its application are associated with better quality control and
sustainable production processes in particular (Singh, Khamba and Singh, 2021).

(b) Target Benchmark Value for OEE in European Automobile Manufacturing

Juraev (2022) asserted that the average period of production effectiveness in European
automobile manufacturing is in the range of 85% to 89%. This benchmark signifies that the
optimum value should be achieved by minimizing possible waste due to manufacturing processes
or for maintenance purposes. This figure denotates uninterrupted use of equipment, little down
time, and maximum products made. In fact, benchmarking performance using the
aforementioned figures is a key factor to compete in the European automotive manufacturing
industry, to achieve operational excellence, and sustainable performance (Kovács et al., 2020).

Part 3

3.1 FMEA table

Component/ Failure Mode Likelihood of Difficulty of Result of Severity Resulting
Item Occurrence Detection Occurrence from Failure (1=not
(1=very low, (1=easy, (Failure Effect) noticeable,
10=very 10=hard) 10=critical)
certain)
Battery Overheating 2 3 Power loss 7
Wiring Short circuit 3 9 Intermittent power 8
loss
Display Screen Malfunction 4 5 Distorted display 6

PCB Solder joint 5 7 Signal loss 9

failure
Connectors Loose 3 8 Intermittent 8
connection connectivity

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In selecting the initial actions that is based on the presented failure mode table, it is the need to
analyze all the parts of the system for the strength of likelihood, detection difficulty, the result of
occurrence, and severity stemming from failure. The goal is to resolve the risky issues timely, as
well as address some fundamental issues that could move the situation to catastrophic results.
For instance, the problem of battery overheating arises because the nonavailability of power due
to it is so serious. Despite the rather unlikely possibility of recent overheating, it is essential to
implement cool-down mechanisms to avoid the overheat and consequent stop at the power loss.

The wiring short circuits those are likely to take place moderately could be included among the
critical issues because of the higher power loss which occurs apart from time intervals. Due to
the challenging task of detecting pipe leaks, applying improved insulation and conducting
regular inspections could be helpful in alleviating this problem and guaranteeing the sufficient
power supply (Rahman et al., 2021). Moderately harmful and very likely damaging error in the
display screen represent medium risk, with medium severity level. To overcome this, wide-
ranging testing during assembly and more thorough quality control measures are suggested in
order to make devices with distorted displays rare, ensuring higher product reliability (Alves et
al., 2021).

PCB solder joint failure is one of those failures which is somehow high in possibilities and which
has the critical effect of signal loss and it should promptly be attended to. It is recommended by
Teng et al. (2020), that besides soldering process improvement and usual inspections, this can be
achieved. These measures can assist to minimize the risk, and as a result, signal integrity and
system failures that could possibly occur should be prevented. Likewise, slack in connectors that
is hardly probable may result in intermittent connectivity issues. Hence, configuration is crucial.
None of the established protection methods can succeed without the detection of interference and
the implementation of secure connectors and regular checks (Adkins et al., 2020).

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References
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2020. Building secure and reliable systems: best practices for designing, implementing,
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Agustiady, T. and Cudney, E.A., 2023. Total productive maintenance: strategies and
implementation guide. CRC press.

Alves, J.B., Marques, B., Dias, P. and Santos, B.S., 2021. Using augmented reality for industrial
quality assurance: a shop floor user study. The International Journal of Advanced
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Bao, J., Guo, D., Li, J. and Zhang, J., 2019. The modelling and operations for the digital twin in
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Braglia, M., Castellano, D. and Gallo, M., 2019. A novel operational approach to equipment
maintenance: TPM and RCM jointly at work. journal of quality in maintenance
engineering, 25(4), pp.612-634.

Chaurey, S., Kalpande, S.D., Gupta, R.C. and Toke, L.K., 2023. A review on the identification of
total productive maintenance critical success factors for effective implementation in the
manufacturing sector. Journal of quality in maintenance engineering, 29(1), pp.114-135.

Cheah, C.K., Prakash, J. and Ong, K.S., 2020. Overall equipment effectiveness: a review and
development of an integrated improvement framework. International Journal of
Productivity and Quality Management, 30(1), pp.46-71.

Hameed, Z., Khan, I.U., Sheikh, Z., Islam, T., Rasheed, M.I. and Naeem, R.M., 2019.
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Juraev, S., 2022. Overall equipment effectiveness (OEE) analysis in CHEP (Doctoral
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Juraev, S., 2022. Overall equipment effectiveness (OEE) analysis in CHEP (Doctoral
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Kadhim, S.A. and Ahmad, M.F.B., 2021. The role of TQM in education: an empirical
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Khanfri, N.E.H., Ouazraoui, N., Simohammed, A. and Sellami, I., 2023. New Hybrid MCDM
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