11

Journal of Applied Sciences Research, 7(1): 11-17, 2011

ISSN 1819-544X
This is a refereed journal and all articles are professionally screened and reviewed

ORIGINAL ARTICLES
Total Productive Maintenance application to reduce Defects of Product

Abdul Talib Bin Bon, Noorazira Karim,

Faculty of Technology Management, Business, Entrepreneurship Universiti Tun Hussein Onn Malaysia, 86400
Parit Raja, Johor, Malaysia

ABSTRACT

This research is conducted to identify factors which contribute to product defects and proposes the
application of TPM in reducing the defects. There are high rate of defects during the manufacturing of gloves.
This results in high numbers of glove pairs that do not meet the standards and requirements as expected by
the customers. The high rate of defects cause the company to bear high cost as consequence of losing raw
material increased operating costs and lower product quality. There are four major factors that cause defects,
human negligence, less quality of raw materials, machines that need maintenances and work procedures. As
for this research, the focus is on the machines in terms of engine damage because engine is a key requirement
in the production of a product. However, this can be reduced through the application of TPM. In performing
this study, researchers make observations, collect the data and analyze the data by using descriptive statistics
and Pareto charts. Respondents are two workers from Glove industry. Feedbacks from both of the respondents
were recorded and the data is analyzed by using Microsoft Excel 2007. In investigating the effectiveness of
the application of TPM to reduce defects, the data before and after the application of TPM is analyzed.

Key words: Product Defect, Quality, Rubber Glove, Total Productive Maintenance

Introduction

The manufacturing industry is a very important sector in the economic development of Malaysia, which
pioneered the development of manufacturing industries to the growth of the economy. So, the government has
implemented various measures to consolidate and strengthen the competitiveness of manufacturing industry.
Product quality is important in the manufacturing industry to ensure that a company has competitive advantage
in the market. Thus, when a product is manufactured by a machine works without complying with the
prescribed specifications, the product will be marketed. When the repulsion is high then it will affect the cost
of having to bear losses and wastage. Therefore, in order to avoid this, the company should take some steps
in handling this problem. If there is experience in using statistical tools of quality, it will help analysts to
analyze this problem. The study was conducted in Glove industry. The company is located in an industrial area
in Klang and it is the largest glove manufacturer in Malaysia. The main objective of this study is to identify
the factors of glove defects and identify the level of implementation of the concept of Total Productive
Maintenance (TPM) in reducing defects in the production of gloves at the Glove industry. The scope of this
study is to identify the factors and the applications of TPM defects on the production machines to reduce
product defects. Concentration is focused on the production of latex gloves.

Material and Method

Research Instruments:

Observations:

The observations used to identify the type of disability, the factors of product defects and the application

Corresponding Author: Dr Abdul Talib Bon, Deputy Dean (R&D), Faculty of Technology Management, Business
and Entrepreneurship. Universiti Tun Hussein Onn Malaysia, 86400 Parit Raja, Johor,
Malaysia. Tel: +6012 7665756
Email: talibon@gmail.com.
J. Appl. Sci. Res., 7(1): 11-17, 2011 12

used to reduce product defects. Factor of defect is identified and the defects can be to reduce.

Data Analysis Method:

Statistical Methods Descriptive:

Researcher use statistical method descriptive on the data that the factory had obtained. Descriptive statistics
of the results obtained are shown through the construction of the line graphs. The data obtained are the data
obtained from the factory Glove industry. These data represent data from the secondary type of damage is
taken with respect to the number of machines and product defect rates of rubber gloves before and after
application of TPM to reduce product defects. The data obtained were analyzed using Microsoft Excel 2007
to see an increase and decrease the data.

Pareto Chart:

Pareto chart is one method for analyzing the data. According to the data collection instruments, data
collected will be analyzed using Pareto chart for the highest frequency among factors identified

Results and Discussions

There are two research questions that must be analyzed first to identify the factors of product defects and
the second is to determine the application of TPM to reduce defects. A brief interview with the researchers
working in the Glove industry explained defects become a major problem in the company's production. Factor
of defect occurs in many parts of the glove manufacturing that involves the use of machinery. Machine used
has resulted in defects in the gloves of Top Glove. To reduce these defects, the company applies TPM to
reduce product defects.

Statistical Methods Descriptive:

Table 1: Number of hour data before and after the implementation of TPM
No. Week Before implementation of TPM After implementation of TPM
------------------------------------------ --------------------------------------------------
Hours % Hours %
1 10 MAY - 16 MAY 154 0.7 - -
2 17MAY - 23 MAY 154 1.4 - -
3 24 MAY - 30 MAY 154 2.4 - -
4 31 MAY - 6 JUNE 154 5.7 - -
5 7 JUNE - 13 JUNE 154 5.11 - -
6 14 JUNE - 20 JUNE 154 11.5 - -
7 21 JUNE - 27 JUNE - - 154 10.5
8 28 JUNE - 4 JULY - - 154 8.7
9 5 JULY - 11 JULY - - 154 6.4
10 12 JULY - 18 JULY - - 154 5.8
11 19 JULY - 25 JULY - - 154 3.5
12 26 JULY - 1 AUG - - 154 2.92
13 2 AUG - 8 AUG - - 154 2.8
14 9 AUG - 15 AUG - - 154 1.4
15 16 AUG - 22 AUG - - 154 0.74
16 23 AUG - 29 AUG - - 154 0.5

Table 1 above shows the number of engine damage data on a weekly basis before and after the
implementation of TPM. Data were recorded by week begins the first week of May 10, 2010 until the 16th
week of August 29, 2010. The increase was significant damage to the engine start in the first week of 0.7%
of the value is increasing in the second week of one-fold of 0.7% and also disturbing the plant. The increase
continued until 20 June 2010, an increase of engine damage increased dramatically from 5.11% to 11.5%. This
situation is difficult for production operations in accordance with the specifications of rubber gloves that had
been set because the machine had to be stopped for overhaul operations.
Table 1 is also adjacent, clearly shows a decrease in damage to the machine after the application of this
method. This situation is clearly seen at week 7 in which the use of this method at the same time of 154
hours, the percentage of reduced engine failure of 10.5%. In addition, the same situation occurs in week 8 of
this method of execution by 8.7% in the rate of machine breakdown occurs and persists until the week to 16
percent of the data showed a decrease engine damage occurs continuously in the same period of the final data
J. Appl. Sci. Res., 7(1): 11-17, 2011 13

shows the percentage of engine damage is 0.5%. According to maintenance supervisor, regular maintenance
of production machinery at the mill to produce data at a zero percent damage in the engine and this can be
achieved with maintenance performed on each day

Fig. 1: An engine damage against the week before and after application of TPM

Figure 1 above, shows a graph of engine damage against the week before and after application of TPM
methods for reducing defects in the gloves of Glove industry. Based on the graph plotted, it is clear to see
that before the application of TPM, the percentage increase in engine damage this week because the machine
must be regularly maintained so that all possible effects can be avoided with earlier. Whereas after the
implementation of TPM on the machine, the graph clearly shown the decline in the percentage of damages
to the machine on a weekly basis. While this method is used, the machine made the maintenance of each week
than before the application of this method is only done two times per month
Table 2 shows the number of defects data glove before and after application of TPM methods of machine
production. This continuing decline in disability rates starting from week 7 until the application of this method
at week 18 of this method is used. Data are listed clearly shows that lowering occurred despite increased
production quality. Before the TPM method is applied to the production machine, the total output of rubber
gloves in the first week of Top Glove is about 1,159,534 pieces of gloves with the glove defects were caused
by the machine of 4416 pieces. In the next week increased production of 1,169,432 pieces of gloves, but the
defect rate is also increased by 4557 copies. Production increased gloves in 3 weeks until week 6, but the
defect rate is also increased. Machine factors that often lead to the production have been damaged a lot of
defects. After the application of TPM rules on the machine with machine maintenance as often as possible and
every day has a satisfactory effect on the production of rubber gloves. As a result, at week 7 after using this
method, the plant increase the production of 1,634,222 pieces of hand strain, but the defect rate dropped gloves
with only 7340 pieces of gloves only. Although the decline is not sharp, but the increase in production per
week had reduced defect rates, is clearly seen at week 8 of 1,733,677 issued gloves and pieces of data on
defect productions decreased by 7080 copies of the glove.

Table 2: Total data glove defects before and after the implementation of TPM
No. Week Before Implementation of TPM After implementation of TPM
------------------------------------------- --------------------------------------------------
Production Defects Production Defects
1 10 MAY - 16 MAY 1,159,534 4416 - -
2 17MAY - 23 MAY 1,169,432 4557 - -
3 24 MAY - 30 MAY 1,287,521 5346 - -
4 31 MAY - 6 JUNE 1,467,444 6211 - -
5 7 JUNE - 13 JUNE 1,548,321 7899 - -
6 14 JUNE - 20 JUNE 1,548,333 7932 - -
7 21 JUNE - 27 JUNE - - 1,634,222 7910
8 28 JUNE - 4 JULY - - 1,733,677 7340
9 5 JULY - 11 JULY - - 1,778,341 7080
10 12 JULY - 18 JULY - - 1,843,521 6813
11 19 JULY - 25 JULY - - 1,843,721 6641
12 26 JULY - 1 AUG - - 1,843,900 6630
13 2 AUG - 8 AUG - - 1,852,764 5911
14 9 AUG - 15 AUG - - 1,854,752 5587
15 16 AUG - 22 AUG - - 1,860,990 5091
16 23 AUG - 29 AUG - - 1,870,981 4830
J. Appl. Sci. Res., 7(1): 11-17, 2011 14

This clearly shows the application of TPM rules are effective on the production machine in the Glove
industry, is because the data are recorded in week 9 until week 16 showed an increase in the quantity of
production every week to see the defect rate is obtained when the increased production. From the results
obtained showed that the rate of glove defects produced decreased from week 9 until week 16 of 4830 pieces
of gloves that have a defect in the increased production of 1,870,981 pieces of gloves.

Fig. 2: Graph of defects of rubber gloves before and after the implementation of TPM

Figure 2 above shows a graph of defects of rubber gloves before and after application of TPM methods
of machine production. What is to be noted that the graph is a graph plotted against the defect rate of weeks.
In each week the plant to increase production volume to look at a product defect occurs on one of these
defects of the machine. Based on the graph clearly shows before using this method, the defect rate increases
every week, but after the application of TPM rules can be acquired defect rate dropped despite increased
production quantities. This is because after the application of TPM, the defect rate decreased due to the
frequent engine maintenance and allow the early detection of plant that would likely cause of machine problem.

Method of Pareto Chart

Table 3: Percentage of defects before and after the implementation of TPM.

NUMBER % of defect before TPM % of defect after TPM
10 MAY - 16 MAY 0.553325733 -
17MAY - 23 MAY 0.634667086 -
24 MAY - 30 MAY 0.77272526 -
31 MAY - 6 JUNE 0.982047697 -
7 JUNE - 13 JUNE 1.091440341 -
14 JUNE - 20 JUNE 1.158148796 -
21 JUNE - 27 JUNE - 1.065338736
28 JUNE - 4 JULY - 1.000186309
5 JULY - 11 JULY - 0.960445719
12 JULY - 18 JULY - 0.9120048
19 JULY - 25 JULY - 0.902576908
26 JULY - 1 AUG - 0.847659851
2 AUG - 8 AUG - 0.804797589
9 AUG - 15 AUG - 0.732550767
16 AUG - 22 AUG - 0.649707951
23 AUG - 29 AUG - 0.525392829

According to Table 3 above, the data show the percentage of defects before and after application of TPM
to reduce product defects. Percent increase substantially clear of defects before the application of TPM, this
is clearly shown from the above data that in the first week showed the percentage of 0.55% increase in the
second week of a total of 0.63%. It is very worrying because the company continued to increase this
percentage in three consecutive weeks until the sixth week of 1.16% per cent of disability. After the application
of TPM per cent disability to be a satisfactory decrease of this application at the seventh week showed a
decline of 1.07%. While at the eighth week of the second week of the application of TPM, the recorded data
showed a decrease of 1.0% percent disability from the previous week. The same situation occurs in the next
week until the week-16 showed a decrease of this percentage to 0.53%. Because of that, case shows that the
application is effectively implemented at the Glove industry to address the problem of defective products.
Table 4 above clearly show the percentage of defects in the form of a table of frequency table shows the
increase of frequency of defects in a withdrawal prior to the implementation of TPM. In the first week of
disability of 0.5%, while the frequency table shows the relative frequency of relatively large at 10.62 this is
a great show the defect occurs in the production. While the second week in the same condition, the defect is
also recorded that there is an increase of 0.63% in the relative frequency of 12:16. Increase in disability is
J. Appl. Sci. Res., 7(1): 11-17, 2011 15

recorded from week to week in which the data still showed an increase and until the sixth week. Defect data
is recorded at a frequency of 1.16% relative 22:39. This clearly shows the defects of rubber gloves due to the
factor increasing the machine

Table 4: Frequency of the defects product data prior to the application of TPM.
Week Value of Defect Before TPM Frequency Relative Cumulative Frequency
6 1.16 22.39 22.39
5 1.09 21.04 43.44
4 0.98 18.92 62.36
3 0.77 14.86 77.22
2 0.63 12.16 89.38
1 0.55 10.62 100.00
SUM 5.18

Fig. 3: Chart Pareto percent of defects before the application of TPM

Figure 3 shows the Pareto charts are constructed based on the frequency table 4.4. Based on the Pareto
chart of the plot, it clearly shows the defect usually exists in the sixth week in which the vertical bars with
the highest percentage of disability of 1.16%. In six weeks, the defect occurs and is keeps on increasing,
leading to detrimental to the plant.

Table 5: Frequency percentage of defects after the application of TPM

Week Value of Defect After TPM Relative Frequency Frequency cumulative
7 1.07 12.75 12.75
8 1.00 11.92 24.67
9 0.96 11.44 36.11
10 0.91 10.85 46.96
11 0.90 10.73 57.69
12 0.84 10.01 67.7
13 0.80 9.54 77.23
14 0.73 8.70 85.94
15 0.65 7.75 93.68
16 0.53 6.32 100.00
SUM8.39

Table 5 shows the frequency schedule of defects per cent after the implementation of TPM to reduce
product defects gloves. In the seventh week after the implementation of the TPM, the defect of 1.07% was
recorded, while the frequency table shows the relative frequency of 12.75 which is quite large, this shows the
great value of the defect occurs in the production. While in the eighth week of the first shows a significant
change where the data is recorded by 1.0% relative frequency of defects in 11.92. Defects declining in the
eighth week are encouraging, and this can be seen in the next week the defect rate decreased significantly after
the application of this TPM. Data are recorded from week to week, until the sixteenth week, the defect data
is recorded at a frequency of 0.53% relative 6:32. This clearly shows the effectiveness of the application of
TPM on the production machine is very satisfying because it is proven to reduce product defects and at the
same time improving the productivity.
Figure 4 shows the Pareto chart was plotted after the application of TPM. After the application of TPM
to reduce defects and increase the added value. This can be evidenced by Table 5 which shows the decline
in the rate of defects than seven weeks until the sixteenth week. Damage often occurs before the machine has
to be solved with the application used by the whole plant is productive maintenance (TPM).
J. Appl. Sci. Res., 7(1): 11-17, 2011 16

Fig. 4: Pareto chart percent disability upon the application of TPM

Discussions:

The formulation can be made from this study concluded that this study is available to answer the research
questions and research objectives. The objective of this study was to determine the effectiveness of the
application of total productive maintenance (TPM) in reducing defects in the production of gloves is glove.
These findings have enabled researchers to obtain answers about the extent of application of TPM in Top
Glove Corporation to reduce product defects. Defect of product must be addressed and the appropriate method
should be applied so as to achieve zero defects. Application of TPM methods of machine production which
causes defects are the most effective step to the factory because this approach can be seen to reduce production
defects and damage the machine. This method can also achieve the objectives of each month to increase
production by preventing the transmission delay caused by machine failure. It was also found, with the TPM
methods of application Glove industry is also appropriate and in line with technological change is happening
now. The second formula can be made from these findings is that, with the application of TPM methods can
improve the efficiency of production machines in the factory to increase production, productivity, save costs
and promote company's image in the eyes of the world.

Conclusions:

Based on the findings of the data collected and the analysis made, it can be identified that the factors of
engine damage is a strong factor affecting the quality of the production of rubber gloves. Engine maintenance
from time to time is an important issue in quality control production of latex gloves in a factory Top Glove.
To optimize and reduce product defects engine damage occurs, the plant should be focused on the maintenance
of machinery to ensure quality production at a satisfactory level. Regular engine maintenance can reduce the
occurrence of a major engine damage affects the rate of defects. There are two aspects of the implementation
of preventive maintenance and maintenance repair. Researchers propose that using the methods that have been
expressed by writers Antero Ollila and Markku (1999) who have expressed a number of methods of reactive
maintenance, preventive maintenance, predictive maintenance, and proactive maintenance. Reactive maintenance
methods can be minimized by using other methods to repair the engine to reduce the defects such as JIT, TQM
and other methods in conjunction with the DPM method for achieving zero defects. While the methods of
preventive maintenance is a routine maintenance schedule has been set. At Top Glove, the method used by
the machine maintenance schedule is 2 times a week. For the measurement of predictive maintenance, which
is the engine used, shows the damage before the issue had ceased. This measure can detect early damage to
the machine. Proactive maintenance is the method also provides experts to improve the existing system of
maintenance of machinery for the purpose of preventing the possibility that will happen on the machine and
can lead to production stops.

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