UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DEVELOPMENT OF TPM SPREADSHEET FOR LABORATORY
Thesis submitted in accordance with the requirements of the University Technical Malaysia Malacca (UTeM) for the Degree of
Bachelor of Engineering (Honours) Manufacturing (Manufacturing Management)
By
THURAIRAJ A/L ARUMUGAM
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
Disahkan ol eh: (Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
TIDAK TERHAD
√
TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Mal aysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
SULIT
JUDUL: DEVELOPMENT OF TPM SPREADSHEET FOR LABORATORY
SESI PENGAJIAN: 2 / 2 0 0 8 -2 0 0 9
Saya THURAIRAJ A/ L ARUMUGAM
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Tesis adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran
ant ara inst it usi pengaj ian t inggi.
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Management). The members of the supervisory committee
are as follow:
DECLARATION
I hereby declare that this report entitled “Development of TPM Spreadsheet for Laboratory” is the result of my own research except as cited in the references.
Signature :
ABSTRACT
ABSTRAK
.
DEDICATION
For my beloved dad and mum Arumugam A/L Karuppiah
Ambika A/P J.M. Cross
Who always been there for me and always prays of me
For my beloved brother Huendran A/L Arumugam
Ramesh A/L Arumugam
ACKNOWLEDGEMENTS
It gives me utmost pleasure to express my gratitude to who have directly or indirectly contributed to the fruition of the compilation. They include;
My supervising lecturer, Mr. Nik Mohd Farid Bin Che Zainal Abidin of which we had an excellent working relationship, and who offered tremendous help and encouragement,
My family, who inspired me weather through the storm and carry on, and last but not least,
Lecturers and friends who helped me.
TABLE OF CONTENT
2. LITERATURE REVIEW ... 5
2.1 Introduction... 5
2.2 Synopsis of Journal ... 5
2.3 Spreadsheet ... 7
2.3.1 Comparison Software... 8
2.3.1.1 Excel – The Selected Spreadsheet ... 9
2.3.2.1 Advantages... 10
2.3.2.2 Disadvantages ... 10
2.4 Background of Total Productive Maintenance ... 11
2.4.1 Definition of TPM... 12
2.4.2 Concept of TPM... 12
2.4.3 Similarities and Difference Between TQM and TPM ... 13
2.4.4 TPM Tools ... 14
2.4.4.1 Autonomous Maintenance ... 15
2.4.4.2 Planned Maintenance ... 15
2.5 TPM Improves Machine Productivity ... 16
2.5.1 Goals of Equipments Maintenance ... 16
2.5.2 TPM Attacks Machine Loss... 17
2.5.3 TPM Focuses on Machine Component Maintenance ... 18
2.6 Lathe Machine... 19
2.6.1 Lathe Machine Maintenance... 20
2.6.2 Preventive Maintenance on Lathe Machine... 21
2.7 Summary ... 21
3. METHODOLOGY ... 22
3.1 Introduction... 22
3.2 Flow Chart ... 22
3.3 Process Flow Chart Explanation ... 25
3.3.1 Problem Statement Identification ... 25
3.3.2 Data ... 25
3.3.3 Literature Review... 26
3.3.4 Primary Data ... 26
3.3.6 Spreadsheet Development... 27
3.4 Function Total Productive Maintenance Spreadsheet... 27
3.5 Selection Software for Development ... 27
3.6 Spreadsheet Development Concept and Planning ... 28
3.7 Summary ... 28
4. PROCESS DEVELOPMENT... 30
4.1 Introduction... 30
4.4.3.1 Project Window ... 36
4.4.3.2 Code Window ... 37
4.4.3.3 Properties Window ... 37
4.5 Spreadsheet Development... 38
4.5.1 Button... 39
4.5.2 UserForm ... 40
4.5.2.1 Creating a UserForm... 41
4.5.2.2 Coding... 42
4.5.2.3 Displaying a UserForm ... 43
4.5.3 Picture ... 44
4.5.3.1 Creating a Picture... 45
4.5.3.2 Displaying a Picture ... 45
4.5.4.1 Procedure for Condition Formatting to a Cell ... 47
4.5.5 If Statements ... 49
4.5.5.1 Formulation for If Statement ... 49
4.6 Summary ... 50
5. RESULT AND ANALYSIS... 51
5.1 Introduction... 51
5.2 Data Input... 51
5.2.1 Lathe Machine Maintenance... 52
5.2.2 Inspection ... 55
5.4.1 Lathe Machine Maintenance Spreadsheet... 61
5.4.2. Comparison ... 62
7. CONCLUSION AND RECOMMENDATION ... 67
REFERENCE ... 69
APPENDIX
A Gant Chart of the Project B Lathe Machine Maintenance C Momac Lathe Machine
LIST OF TABLES
2.1 Comparing the Facilities Offered by the Various Software 9
2.2 Differences TQM and TPM 13
4.2 If Statements 49
LIST OF FIGURES
2.1 Used of spreadsheet by target group 8
2.2 TPM Plant Wide Structure 14
2.3 Pillar of TPM 14
2.4 Condition maintenance keeps parts in useful service for a
natural lifetime 17
2.5 Machine failure have many hidden causes 17
2.6 Lathe Machine (Momac) 20
2.7 Preventive Maintenance 21
3.1 Methodology 23
3.2 Process Flow Chart 24
3.3 Spreadsheet Flow Chart 29
4.1 Record Macro 34
4.2 Macro Dialog Box 34
4.3 Visual Basic Editor Window 36
4.4 Project Window 36
4.5 Code Window 37
4.6 Properties Window 38
4.7 Form Toolbar 39
4.8 Assign Macro to Button 39
4.9 Code Module 40
4.10 UserForm 42
4.11 Display UserForm 43
4.12 Coding 44
4.13 Lathe Machine Picture 45
4.14 Display Picture with Coding 46
4.15 Condition Formatting 47
4.16 Value 47
4.18 Overall Condition Formatting 48
4.19 Formulation of If Statements 50
5.1 Main Menu Worksheet 52
5.2 Lathe Machine Maintenance Worksheet 52
5.3 Lathe Machine Maintenance Checklist 54
5.4 Inspection Worksheet 56
5.5 Daily Inspection Result 59
5.6 Weekly Inspection Result 59
5.7 Month Inspection Result 59
5.8 Daily Inspection Result Graph 60
5.9 Weekly Inspection Result Graph 60
5.10 Monthly Inspection Result Graph 60
5.11 Program Structure of Spreadsheet 62
6.1 UserForm 65
6.2 Code Error 66
LIST OF ABBREVIATIONS
CM - Corrective Maintenance
GUI - Graphic U ser Interface
JIPE - Japanese Institute of Plant Engineers
JIT - Just – In- Time
MI - Maintenance Improvement
MP - Maintenance Performance
OEE - Overall Equipment Effectiveness OTE - Overall Throughput Effectiveness
PM - Preventive Maintenance
PSM - Projek Sarjana Muda
SEM - Structural Equation Modeling
TPM - Total Productive Maintenance
TQM - Total Quality Management
UTeM - Universiti Teknikal Malaysia Melaka VBA - Visual Basic Application
CHAPTER 1
INTRODUCTION
1.1 Background
Nowadays, in manufacturing systems operates with full capacity, with low productivity, and the costs of producing products are high. According to the study reported by Mobley (1990), from 15% to 40% (average 28%) of total production cost is attributed to maintenance activities in the factory. In fact, these costs are associated with maintenance labor and materials and are likely to go even higher in the future with the addition of factory automation through the development of new technologies. Another study conducted by Wireman (1990) in 1989 stated that the estimated cost of maintenance for a selected group of companies increased from $200 billion in 1979 to $600 billion in 1989. Al-Najjar and Alsyouf, (2003) stated that the importance of maintenance function has increased due to its role in keeping and improving the availability, product quality, safety requirements, and plant cost-effectiveness levels as maintenance costs constitute an important part of the operating budget of manufacturing firms
Maintenance techniques and tools are composed of corrective, scheduled, and preventative maintenance (PM). Further detailed research by Mobley (1990) found that corrective maintenance (CM) cost is about three times higher than the same repair made in a preventative mode. Wireman (1990) estimated that about 22% of US firms were using PM methods.
Nakajima (1988) in Japan, which covers the entire life of equipment in every division including planning, manufacturing, and maintenance. It describes a synergistic relationship among all organizational functions, but particularly between production and maintenance, for continuous improvement of product quality, operational efficiency, capacity assurance and safety.
TPM aims to increase the availability and effectiveness of existing equipment in a given situation, through the effort of minimizing input improving and maintaining equipment at optimal level to reduce its life cycle cost and the investment in human resources which results in better hardware utilization.
Currently in the Machine Shop at Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka (UTeM) has improved the maintenance system by developing a checklist in order to keep the lathe machine from breakdown.
1.2 Problem Statement
Currently in the UTeM workshop which has lathe machine facing a major problem regarding on the maintenance activity especially on maintaining the machine and prevent any breakdown.
1.3 Objectives
The objective of this project is:-
1) Develop a Total Productive Maintenance spreadsheet for the lathe machine in UTeM laboratory especially at Faculty of Manufacturing Engineering.
1.4 Scope
The scopes of this study are as follows:
1) The project just focusing on the lathe machine at the laboratory in the Faculty of Manufacturing Engineering.
2) This project is fully using the Visual Basic Application (VBA) in Excel 2003 to develop the spreadsheet.
1.5 Importance of the Project
The importances of the project are:
1.6 Report outline
Chapter 1 explains about the introduction which consists of background, problem statement, objectives, scope and importance of the project. Chapter 2 is about Literature Review that explains in detail about total productive maintenance, spreadsheets and lathe machine. Chapter 3 about Methodology which explain about flow chart of project, flow chart of programming and step to develop of TPM software. Chapter 4 describe in depth about the process development of spreadsheet. Chapter 5 will explain about the result and analysis from the spreadsheet that been developed. The outcome of the result will be used to analyze. Chapter 6 is about discussion which will explain about the problem face and countermeasure during the developed of the spreadsheet. Chapter 7 is conclusion and recommendation which described the overall project and stated the objective that achieved. Mover it also will discussed about the future recommendation which can improve the spreadsheet that been developed.
1.7 Summary
This chapter briefly explains about the project the being carried out. It’s a short introduction on the project which explains about the objective, scope and problem statement. This chapter will be a guideline throughout the project as this project must within the scope as well as to achieved the objective at the end of the project.
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This chapter explains in depth about the literature review on the Total Productive Maintenance (TPM). The literature review also cover about the software especially Microsoft Excel 2003 for the spreadsheet development. Description on the lathe machine discussed carefully. In the other hand, the maintenance activity for the lathe machine is explained in details so that it can be guideline during the process development of the spreadsheet.
2.2 Synopsis of Journal
Chan, F.T.S et al. (2003) stated that the semiconductor industry has gone through significant changes in the last decade. Competition has increased dramatically. Customers focus on product quality, product delivery time and cost of product. Because of these, a company should introduce a quality system to improve and increase both quality and productivity continuously. Total Productive Maintenance (TPM) is a methodology that aims to increase the availability of existing equipment hence reducing the need for further capital investment. Investment in human resources can further result in better hardware utilization, higher product quality and reduced labor costs.
global way. In this sense, the most used methodology is total productive maintenance. TPM with its sustainable pillars guide will create routines that enable that interaction. The main factors that lead to reached levels of excellence of application of the TPM methodology is analysis of the problem operators, maintenance people and managers involved in the productive process. Unfortunately many managers have not noticed yet, that the great asset of the companies is their collaborators and the big responsibility for non-success is due to the managers of the process and the top administration of the companies. Even though several resources are invested for the implementation of a TPM system in the beginning of the process, the organization as a whole is not always really inserted in TPM philosophy. The periodical performance of audit with respective evaluations and feedback in the system still present one of the most positive procedures for the maintenance and improvement of the structure. TPM is an excellent work philosophy that really produces gains in the productive process.
specific practices that lead to improved performance in various environmental and organizational situations.
HuangJohn, S. H. (2003) said that competition and the drive for profits are forcing companies to implement various productivity improvement efforts. Implementation of total productive maintenance TPM techniques has led to significant productivity improvements for individual equipment, particularly in the semiconductor industry. The productivity improvements achieved at the equipment level are significant but insufficient because what a company really needs is a highly efficient system/factory. This is especially true in the discrete manufacturing industry. In this paper, an approach, based on overall equipment effectiveness (OEE), is developed to model the productivity of a manufacturing system in terms of overall throughput effectiveness (OTE). Sensitivity analysis and theory of constraints are used to help identify productivity improvement opportunities. A real-world case study is presented to illustrate the applicability of the approach.
2.3 Spreadsheet
In this project, the program will developed using the spreadsheet. The selection of the spreadsheet was done which from the 3 types of the spreadsheet such as Excel, Lotus and Quattro Pro; Excel was selected as a based spreadsheet in developing the program.
The spreadsheet has been around for some time now and is generally recognized as a valuable and effective aid in business decision making. With this in mind, this project focuses on the spreadsheet and examines those factors deemed to be important in its selection. Among the criteria include the use friendliness of the spreadsheet, compatibility with other software, facilities offered, costs and employee training.
