Autonomous Maintenance: A Case Study on Step -4 Implementation at Detergent Manufacturing Plant Under FMCG Category

Abstract

This comprehensive study delves into the intricate dynamics of Autonomous Maintenance (AM), a pivotal component of the Total Productive Maintenance (TPM) philosophy, as an instrumental strategy employed by companies to elevate the competitiveness of their products. Focusing specifically on the manufacturing sector, with an emphasis on plant and machinery, the research emphasizes the critical role of AM in minimizing losses attributed to breakdowns, thereby contributing to overall cost reduction. The initial stages of AM, encompassing Steps 1, 2, and 3, are dedicated to restoring the fundamental conditions of machinery. These steps involve addressing underlying issues that lead to breakdowns, thus laying the groundwork for a more robust and efficient manufacturing process. In this context, the study underscores the strategic significance of AM in not only rectifying existing problems but also in preventing future disruptions. The crux of this investigation centers on Step 4 of AM, which shifts the focus from restoration to the sustained maintenance of gains achieved in the preceding steps. This step is crucial for ensuring the longevity of improvements and for establishing a proactive approach to maintenance. The study unfolds within the specific setting of a Detergent Manufacturing Plant operating within the Fast-Moving Consumer Goods (FMCG) category, offering a real-world context to the theoretical underpinnings of AM. The research scrutinizes the implementation of Step 4 at the Detergent Manufacturing Plant, elucidating the methodologies employed, challenges encountered, and outcomes realized in the ongoing pursuit of minimizing costly breakdowns. By delving into the intricacies of this implementation, the study seeks to provide nuanced insights into the practical implications and effectiveness of sustaining gains in the manufacturing process through the systematic application of AM principles. Anticipated outcomes of this case study include valuable lessons and best practices that can be extrapolated to benefit companies within the FMCG sector and beyond. As industries strive for operational excellence, the findings of this research are poised to offer actionable insights into the strategic deployment of Autonomous Maintenance for enhancing manufacturing competitiveness and reducing production-related losses.