Integrating Machine Availability and Preventive Maintenance to Improve Productive Efficiency in a Manufacturing Industry

One of the major problems existing in manufacturing industries is low productive efficiency and high frequencies of machine breakdown or downtime. However, equipment maintenance is momentous for improving productive efficiency, methods of integrating preventive maintenance (PM) and Machine availability into improving productive efficiency in manufacturing industries has attracted considerable attention. This work showcased a strategic process improvement plan that can be used to improve production process with low productive efficiency. Lean Six Sigma (LSS) is used as the method for implementation of a successful process improvement. A case study was used to show how a successful implementation of the Lean Six Sigma Define, Measure, Analyze, Improve and Control (DMAIC) approach was implemented, how statistical analysis can be used to identify defects in products, and they were significantly improved. The Study is performed by conducting a qualitative and quantitative analysis using structured questionnaires, surveys, journals with the case a study that boasts of about 600 employees. Investigations showed that an average of 68% contributing to 79% productive efficiency apparently. However, the attempts of the decreasing downtime events and improving efficiency were based on scheduled maintenance checklist plan that is supported by the overall equipment effectiveness (OEE) benchmark as an indicator for affirming improvements. The linear regression model highlighted significant relationship between machine availability and productive efficiency. Proposed solutions using statistical analysis focused on sustainability, introducing a measurement model based on DMAIC criteria that demonstrated a significant improvement of 20% in machine availability, 44.3% in quality, 29.9% in productive efficiency and 57.4% OEE of the targeted case study. The research affirmed Lean Six Sigma (LSS) as a sustainable solution for reducing defects for quality issues, and maximizing efficiency in manufacturing industries, hence, emphasizing on resource optimization and continuous improvement in various study variables. Findings shows that Lean Six Sigma (LSS) as a methodology, is a catalyst for positive change, hence, improving machine performance, and customer satisfaction.