Implementing TPM supported by 5S to improve the availability of an automotive production line

I. M. Ribeiro, R. Godina, C. Pimentel, F. Silva, J. C. O. Matias

Research output: Contribution to journalConference articlepeer-review

5 Citations (Scopus)


The maintenance management is a topic of strategic importance for automotive manufacturers. In fact, an effective maintenance process and a preventive maintenance (PM) procedure can significantly reduce the risk of equipment failures that can lead to downtime on the production lines. However, due to the complexity of an automotive production system, the risk of failure on a crucial piece of the production equipment cannot be entirely avoided. The study made in this paper aims at improving the availability of a critical production line through the total productive maintenance (TPM) methodology and supported by Lean Maintenance tools. An analysis is made of the initial condition of the line where the main problems are identified by employing several tools for this purpose, such as Mean Time between Failures (MTBF), Mean Time to Repair (MTTR), Overall Equipment Efficiency (OEE) and Availability (A). In response to the identified problems, an action plan is developed and implemented in order to find the root cause of the high number of malfunctions and faults in one of the line's equipment with the use of 5S tools, visual management, and maintenance progress, as well as the development of a training program to increase operators' skills. The results of such actions were positive as the line became more organized, the value of the MTBF increased, the MTTR value decreased, and consequently the overall availability increased.

Original languageEnglish
Pages (from-to)1574-1581
Number of pages8
JournalProcedia Manufacturing
Publication statusPublished - 2019
Event29th International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2019 - Limerick, Ireland
Duration: 24 Jun 201928 Jun 2019


  • 5S
  • Automotive industry
  • Availability
  • Lean Thinking
  • OEE
  • TPM

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