Continuous improvement in maintenance: a case study in the automotive industry involving Lean tools

Maintenance function assumes a key role in today’s industry. The automotive industry is not an exception and there are strict rules to comply with. Indeed, the IATF 16949:2016 imposes the implementation of key performance indicator as a mean to control the overall manufacturing performance. This wor...

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Bibliographic Details
Published in:Procedia manufacturing 2019, Vol.38, p.1582-1591
Main Authors: Pinto, G.F.L., Silva, F.J.G., Campilho, R.D.S.G., Casais, R.B., Fernandes, A.J., Baptista, A.
Format: Article
Language:English
Subjects:
Automotiveindustry
Continuous improvement
Lean
Maintenance
MTBF
MTTR
OEE
Performance Indicators
SMED
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Summary:Maintenance function assumes a key role in today’s industry. The automotive industry is not an exception and there are strict rules to comply with. Indeed, the IATF 16949:2016 imposes the implementation of key performance indicator as a mean to control the overall manufacturing performance. This work presents a case study carried out in a multinational company related with the production of parts for the automotive industry where it was necessary to implement key performance indicators to comply with the IATF 16949: 2016 standard and a model was also created for the management of spare parts linked to the maintenance of existing equipment. The introduction of these changes forced the application of some Lean tools, with a view to improving procedures and information flows. The work was completed successfully, and key performance indicators were implemented, whose support data, which is now collected and calculated automatically on a routine basis, and the spare-parts management was validated with a view to optimization of warehouse space and at a conveniently low inventory level in this type of parts, without endangering critical equipment in production. The SMED methodology was applied, which allowed the setup time to be reduced by 11%, and the Lean 5S tool was used to organize the mould exchange activities. An OEE of more than 90% has been achieved.
ISSN:2351-9789
2351-9789
DOI:10.1016/j.promfg.2020.01.127