Special Issue Article Open Access

Analysis and Implementation of Total Productive maintenance, Kanban and JIT Systems In Small Scale Polymer Industry

Abstract

The plastic 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, company should introduce a quality system to improve and increase both quality and productivity continuously. The objective of this paper is to increase the productivity and quality of work by implementing the TPM (Total Productive Maintenance) Pillars and lean concepts of Just-In-Time (JIT) and Kanban. In this paper, we have taken the case study of small scale manufacturing unit. Implementation of the Kanban system resulted in reduction of inventory to minimum levels besides increasing flexibility of manufacturing. Successful implementation of the Kanban system furthermore reduces operational costs, consequently increases market competitiveness. In a JIT environment, materials are purchased and produced as and when it is needed. Research on Kanban, JIT and TPM generally investigates the implementation and impact of these manufacturing programs in isolation. However, many researchers believe and argue conceptually the value of understanding the joint implementation and effect of manufacturing programs. This study investigates the practices of the three programs simultaneously. We find that there is evidence supporting the compatibility of the practices and that manufacturing performance is associated with the level of implementation of both socially- and technically-oriented practices of the three programs. After implementing TPM Pillars, JIT and Kanban in this industry, we have completed our objective by increasing productivity and Quality of product and also reduced the scrap losses of this industry. We have found good improvements in the OEE value also.

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