Development Of TPM Spreadsheet For Laboratory.

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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)

THURAIRAJ A/L ARUMUGAM

Faculty of Manufacturing Engineering 2009

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UTeM Library (Pind.1/2007)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PSM

Disahkan ol eh:

(TANDATANGAN PENULIS) Alamat Tet ap:

NO 14, LORONG KLEDANG UTARAR 3, TAMAN GAMELAN 31450

IPOH PERAK

Tarikh: _______________________

(TANDATANGAN PENYELIA) Cop Rasmi:

Tarikh: _______________________ (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.

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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:

Nik Mohd Farid Bin Che Zainal Abidin (PSM Supervisor)

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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 :

Author’s Name : Thurairaj A/L Arumugam Date :

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ABSTRACT

This project is about developing a spreadsheet for maintenance activity on the lathe machine in Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka. Maintenance for the machine is important because to prevent breakdown as well as to increase the life time of the machine. Thus, Total Productive Maintenance (TPM) plays a big role in that process developed of the spreadsheet and to carry out the maintenance work effectively. The objective of the project is to develop a total productive maintenance spreadsheet for the lathe machine in UTeM laboratory. The TPM spreadsheet based programming to improve the maintenance system in machine shop. An observation done to find the suitable maintenance activity that need to carry out on the lathe machine in order to developed a effective spreadsheet for the maintenance. However, the scope of the project is performed to develop the TPM spreadsheet on the lathe machine at the laboratory in the Faculty of Manufacturing Engineering, UTeM. The spreadsheet used Microsoft excel VBA (Visual Basic for Application) 2003 and the project just focusing the inspection and maintenance.

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ABSTRAK

Projek ini berkaitan penghasilan lebaran sebaran untuk kegunaan aktiviti penyelenggaran pada mesin larik di Fakulti Kejuruteraan Pembuataan, Universiti Teknikal Malaysia Melaka. Penyelenggaran penting kerana ia mengelakkan mesin dari rosak serta dapat meningkatkan jangka hayat mesin berkenaan. Oleh yang demikian, projek ini memainkan peranan yang penting dalam usaha menghasilkan lebaran sebaran serta menjalankan penyelenggaran dengan lebih sempurna. Objektif projek ini adalah untuk menghasilkan lebaran sebaran penyelenggaran untuk mesin larik di UTeM. Sistem yang dihasilkan adalah berdasarkan kaedah program untuk meningkatkan penyelenggaran di bengkel. Satu prosess pemantauan dijalankan bagi mengenalpasti penyelenggaran yang sesuai dilaksanakan di bengkel berkenaan. Walaubagaimanapun, skop projek ini adalah untuk menghasilkan sistem penyelenggaran dengan menggunakan “spreadsheet” untuk mesin larik di bengkel Fakulti Kejuruteraan Pembuatan, UTeM. Microsoft excel VBA 2003 digunakan dalam penghasilan sistem ini serta projek ini hanya mengfokuskan kepada penyelenggaran dan pemeriksaan.

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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

For my beloved sister Kasturi Shalini A/P Arumugam

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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.

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TABLE OF CONTENT

Abstract ... i

Abstrak ... ii

Dedication ... iii

Acknowledgement ... iv

Table of Content ... v

List of Tables ... x

List of Figures ... xi

List Abbreviations... xiii

1. INTRODUCTION... 1

1.1 Background ... 1

1.2 Problem Statement ... 2

1.3 Objective ... 3

1.4 Scope of Project ... 3

1.5 Importance of Project... 3

1.6 Report Outline... 4

1.7 Summary ... 4

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

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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

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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

4.2 System Development ... 30

4.3 Microsoft Excel 2003... 31

4.4 Visual Basic Application in Excel ... 31

4.4.1 Macros... 32

4.4.3 Recording a Macros ... 32

4.4.3. Visual Basic Editor ... 35

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

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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

5.3. Result ... 56

5.3.1 Daily Inspection ... 57

5.3.2 Weekly Inspection ... 58

5.3.3 Monthly Inspection ... 58

5.4 Analysis... 61

5.4.1 Lathe Machine Maintenance Spreadsheet... 61

5.4.2. Comparison ... 62

5.5 Summary ... 63

6. DISCUSSION ... 64

6.1 Introduction... 64

6.2 UserForm ... 64

6.3 Visual Basic Code... 66

6.5 Summary ... 66

7. CONCLUSION AND RECOMMENDATION ... 67

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REFERENCE ... 69

APPENDIX

A Gant Chart of the Project B Lathe Machine Maintenance C Momac Lathe Machine

D Momac Lathe Machine Parts Name E Current Maintenance Checklist

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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

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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

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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

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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

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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.

In response to the maintenance and support problems encountered in manufacturing environments, the Japanese developed and introduced the concept of total productive

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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.

In order to overcome this problem especially on maintaining the lathe machine a TPM spreadsheet is developed. It is necessary because the technician in the laboratory can determine which machine needs to carried out maintenance work and to identified the machine that cause problems frequently.

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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) To study the current TPM method applied in the manufacturing industry 2) To identify the method used to carry out the maintenance in laboratory.

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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.

In addition, it will give a brief idea on the project that being carried out and the purpose of the project in general.

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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.

Rodrigues, C. and Hatakeyama, K. (2006) defined that the interaction between maintenance and production has been of great intensity in the manufacturing

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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.

McKone, K.F. (1999) describes the investigation of the relationship between Total Productive Maintenance (TPM) and manufacturing performance (MP) through Structural Equation Modeling (SEM). TPM has a positive and significant relationship with low cost, high levels of quality, and strong delivery performance. The relationship between TPM and MP can be explained by both direct and indirect relationships. In particular, there is a significant and positive indirect relationship between TPM and MP through Just-In-Time (JIT) practices. The results of the analyses indicate that TPM has a strong positive impact on multiple dimensions of MP. While TPM directly impacts MP, there is also a strong indirect relationship between TPM and MP through JIT. Maintenance programs have long been used as a means to control manufacturing costs. TPM does more than control costs; it can improve dimensions of cost, quality, and delivery. TPM can be a strong contributor to the strength of the organization and has the ability to improve MP. World Class Manufacturing programs, such as JIT, TQM, and TPM, should not be evaluated in isolation. They are closely related and in combination can help foster better MP. The authors recommend that practitioners pay closer attention to their maintenance management practices and their impact not only on costs but also on quality and delivery performance. Our future research will provide additional details about

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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.

Earlier research conducted in 1993 by Newcastle Business School aimed at assessing IT usage in a large number of businesses revealed that in terms of software

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