Reduction of downtime through the design of TPM and the implementation of some techniques of SMED system at high speed packaging lines

Abstract

This project was developed at a pharmaceutical facility located in the eastern area of Puerto Rico. The company manufactures oral contraceptives and analgesics. In the analgesic branch a new product is being introduced, and two packaging lines were acquired. Together both lines, called OTC-1 and OTC-2, pack six product presentations. The OTC-1 line packs four presentations that are distributed as follows: 50 count (oval and round) and 100 count (oval and round). The OTC-2 line packs a 24 count (oval and round). Our project consisted of two stages. First we studied the actual conditions of the machinery for the lines. Afterwards we pointed out the opportunities that would help us achieve our goal: improving the available time for production in the two high-speed packaging lines. To achieve this goal we planned the design of total productive maintenance (TPM) and implementation of a setup time reduction system known as single minute exchange of die (SMED).