Impact of Lean Technology on Overall Equipment Effectiveness

Author Name(s): Elvira D. Khisamova, Irina A. Kodolova, Aliya A. Kucherbaeva
Author Email: ela_76@mail.ru

Abstract

The spatio-temporal production process is considered and the necessity of its organization on the basis of lean technology is justified. The role of the basic tool for organizing a lean production flow – Total Productive Maintenance (TPM) – is noted and the overall equipment effectiveness (OEE) used in continuous production has been calculated. It was found that the system of general maintenance and repair of equipment is a key tool to improve the efficiency of the organization of production processes in continuous sequential production. From our point of view, the production process is a set of interrelated main, auxiliary and servicing processes of using labor, material and financial resources per unit of time per unit of raw materials, materials, semi-finished products for the purpose of releasing the required quantity of products of the required quality with established using interrelated methods and methods of rational combination of living labor with the means of production, taking into account the minimization of production risks.

Introduction

Production is a key stage in the product life cycle, and the end results of the enterprise’s operation depend critically on how rationally and economically efficient it is organized. It is at the stage of implementation of production processes that technical and economic indicators are laid. Achieving the best values of the indicators provides the company with profit growth, increasing profitability of production, expanding the market for products and improving the competitiveness of the enterprise [5]. In our opinion, it is necessary to consider the production process from the point of view of progressive methods of organizing production, namely lean technologies. The basic tool for organizing lean production flow is Total Productive Maintenance (TPM) [6]. The main aspects of TPM are: improving the performance and service life of equipment due to better care and attention to the requirements for operation; increasing the productivity and quality of equipment maintenance through training and increasing workers’ motivation; collective identification of the causes of malfunctions, search for opportunities to improve performance due to redevelopment of working premises, changes in changeover operations [8].

Conclusion

In the course of studying the organization of the production process at the enterprise under investigation, it was established that the process for the production of bricks functions in accordance with modern technologies for the production of ceramic products from clay. The production line is fully automated, which eliminates the influence of the human factor. Manufactured products are checked for compliance with quality standards. However, as shown by the analysis of the results of the enterprise, production has a low profitability, the cost growth rate outpaces the revenue growth rate, which leads to a decrease in the company’s marginal profit and adversely affects the main performance indicators. One of the tasks of the enterprise for the near future is to increase the competitiveness of the products manufactured by reducing its cost price while maintaining a given level of quality. The study found that the system of general maintenance and repair of equipment is a key tool to improve the efficiency of the organization of production processes in continuous sequential production. First, the main types of losses in continuous production are the loss of time due to equipment downtime, while the TPM system is aimed at reducing emergency downtime and increasing the available time of equipment operation. Secondly, the system TPM is not only aimed at reducing equipment breakdowns, by planning preventive work, but also at increasing the efficiency of work on eliminating emergency situations on the production line. To assess the effectiveness of planned work, the author proposed an indicator of the ratio of emergency and planned work. By tracking the dynamics of this indicator, it is possible to assess the results of the implemented measures to improve the efficiency of emergency operations, as well as the number of equipment breakdowns. It should be noted that the creation of a plan of preventive work, regulations of periodic maintenance of equipment, maps of daily maintenance of equipment contributes to the standardization of these works, which allows them to perform faster and more efficiently.

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