Banbury Mixer O.E.E.

analysis
A TOTAL PRODUCTIVE MAINTENANCE APPROACH CEAT TYRES, MUMBAI BHANDUP PLANT

RAVI AGARWAL IIT GANDHINAGAR

Objective
Analysis of O.E.E. of Banbury mixer-2 using T.P.M

approach.

OEE is a key metric in Total Productive Maintenance programs

and gives us a consistent way to measure the effectiveness of TPM and other initiatives by providing an overall framework for measuring Production Efficiency.

O.E.E. lies between 40% to 85% World standard is 85% of Toyota.

Banbury mixer
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Internal batch mixer Raw material are mixed to form a basic semi-solid

material which is then extruded to form rubber sheets.

Total productive Maintenance

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A company-wide team-based effort to build quality into

equipment and to improve overall equipment effectiveness Total

all employees are involved it aims to eliminate all accidents, defects and breakdowns actions are performed while production goes on troubles for production are minimized keep in good condition repair, clean, lubricate

Productive

Maintenance

Overall Equipment Effectiveness

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Planning V/s Reality

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Abnormality analysis
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Corrective measures
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Kaizen
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kai means change, zen means good. Small improvements on continual basis..

Major Kaizens at Ceat Plant Broken guards over machine parts to be replaced. Unsafe work surroundings to be improved and properly

Re-designed. Improper design for cable routing to be properly designed. Proper calibration of Pressure Gauges and other important parts of Banbury mixer.

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One Point Lesson (OPL)

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Basic information sheet: essential basic information practical knowhow and know-how of methods:
Maintenance activities as e.g. filter changing. Small repair works, cleaning, lubricating.

Major OPL to be implemented at Ceat Tyres, Bhandup plant are: Guarding the machine parts by aligning them properly. Damaged things to be immediately reported and replaced. After finishing the job, tools and materials should be put back to their original places. Proper arrangement of cable routing and avoiding cable slagging. Open cable should be immediately removed. Proper way of collecting oil and improve housekeeping.

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Make Standards
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Most important technique of implementing and sustaining

TPM. Done by making the important and basic needed improvements as standards by documenting them. Major Standards at Ceat Tyres:

Standard for Proper Routing of cables. Standard for avoiding slagging of cables. Standards stating removing of open cables. Standards for regular cleaning and improved housekeeping. Standards for identification of parts properly to avoid hindrance in operation.

For abnormalities due to basic faults

Typical engineering abnormalities

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Conclusion
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O.E.E. trends highlight the present state of manufacturing

and resource utilization at CEAT tyres.

Average O.E.E. being 59% with world standard being 85%. Abnormality analysis highlight the basic problems and

point to the ultimate solution of an effective TPM approach.