Total Productive Manufacturing
Supervisor(s):
Dr. Nahed Sobhi
Team
Members:
Mohamed Mohsin Husein
Omar Mohamed Gaafar
Sherif Farid Fahmy
Mohamed El Shater
General
Objectives:
The aim of the project was to eliminate the presence of long waiting lines in
the Mitsubishi car service center and the deficiency in the inventory control
system. Which will is reflected in a decrease in customer satisfaction. This
would be done through the following:
- Using Total Productive Maintenance (TPM) to optimize waiting lines and reduce
worker's idle time.
- Using statistical analysis to improve the inventory of spare parts and promote
customers' awareness.
Achievements:
TPM was defined to be "a maintenance program, which involve a newly defined
concept for maintenance plants and equipment. TPM creates a culture where
craft-workers interchange skills and share tasks to assure completion of jobs
and minimization of waiting lines".
The objectives were approached as follows:
- For TPM implementation the skill level required for all the jobs in the
service center (mechanical, electrical, and body works) was determined by
setting criteria to determine the skill level required for each job, then the
developing detailed job descriptions and finally a region for the shared tasks
zone was bounded.
- For statistical analysis the data obtained for medium moving spare parts was
analyzed and a bar chart was developed to be given as a guide to the service
center and to customers.
The Stages of implementation of TPM in the factory were studied and done
theoretically but were not actually implemented. However, the study was
discussed with the manager with Mitsubishi service center and he issued a
validation letter in which it was stated that it would be implemented in the
near future after further examination of the study. Those stages consist of:
- TPM preparation which is includes setting the goa;s and objectives of TPM and
organize a plan.
- TPM Kick off which consists of doing a presentation that introduces the
prepared plan to all employees.
- TPM implementation in which Plan is executed and skill level for each job is
determined so as to assign the right worker to do it.
- TPM stabilization.
