Implementation of Kaizen and Poka-yoke to Enhance Overall Equipment Performance

A case study

Anil S. Badiger, R. Gandhinathan, V. N. Gaitonde, Rajesh S. Jangaler

(Kaizen 06)

Abstract

Focused (Continuous) improvement is an essential requirement for sustaining and gaining a competitive advantage for the organizations.

A successful continuous improvement program is one where in the operational defects are eliminated at the root cause level and are prevented from reoccurring.

Total productive maintenance (TPM) methodology is a proven approach to increase overall equipment effectiveness (OEE) of equipment. It consists of eight pillars, focused improvement and autonomous maintenance are two important pillars amongst them to enhance overall equipment performance.

These pillars aim to educate the participants in the concepts and philosophy of equipment maintenance and give them an opportunity to develop their skills and confidence.

In the present work an attempt is made to identify the areas of improvement in equipment, kaizen and poka-yoke are implemented to enhance its overall performance to increase the productivity.

Why-why method of root cause analysis is used to eliminate the causes. The OEE of the equipment is increased from 49.9% to 74.68%.

The improved OEE resulted increase in availability, better utilizetion of resources, high quality products and also raised employee morale and confidence.

Keywords: Overall equipment effectiveness, Availability, Equipment performance, Focused improvement, Autonomous maintenenace, Productivity.