Improvement of Overall Equipment Effectiveness using Total Productive Maintenance and Failure Mode Effect Analysis in Blast Furnace of Iron & Steel Industry

This paper aims for conducting Total Preventive Management significantly using Failure Mode Effect Analysis in Blast Furnace to improve productivity quality and reliability of Iron and Steel Industries. Many organisation experience a halt in operations as a result of damaged production machines; as a result, customer demand is not met, and productivity suffers. This study is conducted at Jaiswal Nico private limited, Raipur. Blast furnace where general equipments are very delicate and need to be replaced frequently. It results in slow down of operation. Calculation of overall equipment effectiveness is affected due to low efficiency and lack of continuous analysis. TPM-FMEA technique was much required for blast furnace to eradicate the general failure. In this paper first the general problem where identified for various equipment in blast furnace, the TPM is done and OEE is calculated. Again FMEA is applied to the same process and OEE is calculated again. Results are compared for values of OEE before FMEA (Financial Year 2018-19) and after FMEA (Financial Year 2019-20). Results are being validated using SPSS Software. Value of Overall Equipment Effectiveness is more in financial year 2019-20. After FMEA four components where identified which have high failure rate. Six big losses are also calculated to identify the time losses more minutely. TPM-FMEA is more comprehensive then alone TPM or alone FMEA. It gives more detail on failure root cause and potential failure also. During maintenance TPM-FMEA can be applied quarterly or six monthly so as to reduce the utilization losses and speed losses from time to time.