Application of Total Productive Maintenance to Improve OEE of the MESPACK H-180 Series Liquid Filling Machine

This study examines the impact of Total Productive Maintenance (TPM) interventions on improving the Overall Equipment Effectiveness (OEE) of the MESPACK H-180 Series In-Line Liquid Filling Machine. The machine's baseline OEE of 54.74% falls short of the company's 75% target, necessitating strategic improvements. Using Root Cause Analysis (RCA), correlation analysis, and Pareto analysis, the study identifies Reduced Speed (-0.868) and Setup & Adjustment Losses (-0.907) as the most significant contributors to OEE decline, followed by Idling & Minor Stops (-0.491) and Equipment Failure (-0.174). Pareto analysis highlights insufficient training (16.13%), reactive maintenance (29.03%), and lack of routine inspections (38.71%) as key inefficiency drivers. Predictive modeling indicates that an Aggressive Improvement scenario (90% availability, 85% performance) successfully meets the company’s goal, achieving an OEE of 76.27%. Additionally, a Maximum Optimization approach (95% availability, 90% performance) pushes OEE further to 84.18%, demonstrating that availability and performance enhancements are key to efficiency gains. Findings suggest that structured TPM strategies, including operator training, preventive maintenance, and systematic monitoring, are crucial for sustained OEE improvements, reduced downtime, and enhanced production reliability. This study provides a data-driven framework for optimizing manufacturing efficiency through TPM methodologies.