Proactive mechanical maintenance application supported by total productive maintenance in a polyester film production facility

TPM (Total Productive Maintenance) is a management system that aims to extend the life of equipment, preventing failures and increase productivity in production plants. In the TPM management system, OEE (Overall Equipment Effectiveness) and MTBF (Mean Time Between Failures) values are important production and maintenance performance measures that are standardized and accepted among international companies. In this study, the design and implementation results of a proactive mechanical maintenance program with TPM method on the L5 line in a polyester film plant were evaluated in terms of OEE and MTBF performance measures. A high OEE value indicates that the plant is operating efficiently. OEE values above 60% are considered good, while values above 85% are considered a world-class performance indicator. MTBF refers to the average time between the failure of an equipment and the next failure. The aim of the study is to evaluate the mechanical maintenance activities in line with the factory targets with the TPM method. Factory maintenance targets are set as OEE and MTBF at the beginning of each season. The OEE performance obtained because of the study was realized using case study and data analysis methods. As data sources, production and maintenance reports recorded by the company on excel spreadsheets and documentation related to TPM implementation were used. As a result of the study, it was seen that the international standard value of 80% and above OEE performance value was achieved for the L5 line of the factory. The findings obtained in the study are as follows. OEE: 86% average value complies with the standards. MTBF: 14.95 days/month average value is very close to the company targets. These results show that the implemented TPM proactive machine maintenance program is beneficial.