Indian Journal of Engineering & Materials Sciences

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Implementation of Total Productive Maintenance to Improve Productivity of Rolling Mill


Affiliations
1 Department of Mechanical Engineering, OP Jindal University, Raigarh Chhattisgarh 496 001, India
2 Nalwa Steel and Power Limited, Raigarh Chhattisgarh 496 001, India

The main objective of this study is to improve productivity of the rolling mill of the steel plant by implementing Total Productive Maintenance (TPM). Due to the increasing demand of steel products, it is necessary to improve productivity of the rolling mill as various types of structural items are produced by rolling mills. Machine maintenance plays an important role in achieving maximum production in steel industry. The TPM was implemented in an integrated steel plant and its effect on production was observed. First, six months of data were collected, and then the breakdowns were analyzed using TPM. Then, TPM was implemented for the next six months and the productivity of the rolling mill was analyzed. The productivity of the rolling mill was enhanced by~10% by implementing TPM, and equipment availability was also improved by ~14%. However, after the implementation of TPM, the overall equipment efficiency (OEE) reached about 80.19%, which is close to the world steel OEE of 85%.

Keywords

Rolling mill, Equipment availability, OEE, TPM, Productivity
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  • Implementation of Total Productive Maintenance to Improve Productivity of Rolling Mill

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Authors

Sardar Singh Rathi
Department of Mechanical Engineering, OP Jindal University, Raigarh Chhattisgarh 496 001, India
Mithilesh Kumar Sahu
Department of Mechanical Engineering, OP Jindal University, Raigarh Chhattisgarh 496 001, India
Sanjeev Kumar
Nalwa Steel and Power Limited, Raigarh Chhattisgarh 496 001, India

Abstract


The main objective of this study is to improve productivity of the rolling mill of the steel plant by implementing Total Productive Maintenance (TPM). Due to the increasing demand of steel products, it is necessary to improve productivity of the rolling mill as various types of structural items are produced by rolling mills. Machine maintenance plays an important role in achieving maximum production in steel industry. The TPM was implemented in an integrated steel plant and its effect on production was observed. First, six months of data were collected, and then the breakdowns were analyzed using TPM. Then, TPM was implemented for the next six months and the productivity of the rolling mill was analyzed. The productivity of the rolling mill was enhanced by~10% by implementing TPM, and equipment availability was also improved by ~14%. However, after the implementation of TPM, the overall equipment efficiency (OEE) reached about 80.19%, which is close to the world steel OEE of 85%.

Keywords


Rolling mill, Equipment availability, OEE, TPM, Productivity