SUNConferences, Southern African Institute for Industrial Engineering 2014

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EXPLORING THE NEED FOR PLANNED MAINTENANCE IN REPONSE TO LOW PRODUCTIVITY AT A HEAVY STEEL MANUFACTURER
Dieter Hartmann, Takura Malaba, Chupisa Saasa

Last modified: 2014-06-26

Abstract


A large steel fabricator observed poor productivity and bottlenecking in their shot-blasting section. This study aimed to identify the causes of low productivity and further identify improvement opportunities. The shot-blasting section was found to add value only 19% of the time. Production records revealed that downtime accounted for 61% of machine non-availability, whilst time study data further revealed that idle time accounted for 11%, rework 9% and yield 21%; all of which contributed to low productivity levels. These factors were further analysed using fish bone  diagrams, 5-Why analyses, and interviews to determine root causes of low productivity in shot-blasting. It was concluded that the  chief cause of downtime is a lack of planned preventative maintenance (PPM), with downtime, low yield and rework being attributable to a lack of PPM. Implementing PPM would significantly improve throughput at shot-blasting and significantly reduce downtime costs.


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