Improvement of overall equipment effectiveness of forging machines by reducing the occurrences of unscheduled downtime at Aichi Forging Co. of Asia, Inc., Sta. Rosa, Laguna, Philippines

Date

6-2016

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Angelo C. Ani

Abstract

Aichi Forging Co. of Asia Inc. (AFC) is a manufacturer of forged products, specifically, automotive component parts. As part of the Total Productive Maintenance (TPM) of AFC, production effectiveness is being measured using Overall Equipment Effectiveness (OEE). Currently, AFC incurred an average OEE per month of 57.87%, lower that the target 65% set by the company. This study aimed to increase the average OEE to at least 65% by reducing the occurrences of unscheduled downtime of forging machines. OEE metrics of effectiveness and why-why analysis were used to identify the root causes of problem. Proposed actions to address these root causes include change of inspection sampling technique, completion of die check sheets, system of disciplinary actions to die assemblers, and installation of automatic lubricant sprayer. From these four recommendations, installation of lubricant sprayer was not implemented due to the associated high cost of implementation. Upon full implementation of the three other recommendations, the current average unscheduled downtime is estimated to decrease by 50.56% which will yield to Php 125, 788. 56 monthly savings from the occurrence of additional overtime labor cost. Furthermore, the current OEE is expected to increase to 65.01% per month. The estimated cost of implementation is Php 1, 961. 25 per month.

Language

English

Location

UPLB College of Engineering and Agro-Industrial Technology (CEAT)

Call Number

LG 993 2016 E66 D36

Document Type

Thesis

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