Effect of autonomous maintenance on plant reliability and overall equipment efficiency (a case study of lafarge surma cement limited, Bangladesh)

Abstract

This thesis work highlights one of the powerful approaches to improve reliability and predictability of the plant using Autonomous Maintenance (AM), a pillar of Total Productive Maintenance (TPM). This explains the underlying concepts, issues, and benefits of AM implementation through a case study. The company discussed in this study is a Multinational Company (MNC), manufacturing cement in Bangladesh. Lafarge Surma Cement Limited (LSCL) has a good organizational structure to support the AM but lack of understanding they are paying a lot. In this thesis work I collected all the stoppages and segregated them in different classes. Then all the incidental stoppages were analyzed and identified the stoppages which could be avoided if the AM was in place. It was also highlighted what is the effect of those incidental stoppages on Plant Reliability and on Overall Plant Effectiveness. Some tools were developed to support the LSCL for better management of the stoppages and also provided some tools to help them implementing the AM. Finally some recommendations were made based on the findings.