MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING CAPSTONE PROJECT INDUSTRIAL MANAGEMENT APPLYING DIGITALIZATION TO ENHANCE THE EFFECTIVENESS OF TOTAL PRODUCTIVE MAINTENANCE (TPM): A CASE STUDY OF BOSCH VIET NAM LECTURER: HUYNH ANH TUAN, MA. STUDENT: NGUYEN THANH TRUONG SKL012052 Ho Chi Minh City, November 2023 MINISTRY OF EDUCATION & TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF ECONOMICS THESIS APPLYING DIGITALIZATION TO ENHANCE THE EFFECTIVENESS OF TOTAL PRODUCTIVE MAINTENANCE (TPM): A CASE STUDY OF BOSCH VIET NAM Student : Nguyen Thanh Truong Student Id : 20124345 Year : 2020 Major : Industrial Management Advisor : Huynh Anh Tuan, MA. Ho Chi Minh City, November 2023 COMMENTS OF ADVISOR ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- HCMC, …. Advisor i COMMENTS OF REVIEWER ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------- HCMC, ….
Reviewer ii ACKNOWLEDGEMENTS The author would like to convey my heartfelt gratitude to the teachers at the Faculty of Economics, Ho Chi Minh City University of Technology and Education. Your teachings during my years at the university have bestowed invaluable knowledge upon me. The learnings acquired are not only foundational for my research but also significant as The author ventures into new professional environments and the whole career path. The author extends my deepest and most sincere thanks to Dr.
Huynh Anh Tuan, whose love, support, and guidance have been unwavering and instrumental in the completion of my Graduation Thesis. The author is also grateful to the Board of Directors of Bosch Vietnam Co. for granting me the opportunity and conducive environment to gain practical experience at the company. A special thanks to Mr.
Tran Anh Khoa and Mr. Nguyen Thanh Trung from the TEF 3.3 department – your support and facilitation have been crucial in enabling the completion of my graduation thesis during my internship. Recognizing the inevitable limitations in my thesis work, The author deeply values constructive feedback from my teachers, which has been essential in refining my essay with my best effort. Sincere appreciation from the author.
Student name Nguyen Thanh Truong iii LIST OF ABBREVIATION Abbreviation Explanation ERP Enterprise Resource Planning TEF Technical Function CVT Continously Variable Transmission OEE Overall Equipment Effectiveness TPM Total Productive Maintenance MTBF Mean Time Between Fauilure TpP Tilburg Plant HcP Ho Chi Minh City Plant AM Autonomous Maintenance WI Work Instruction MSE Manufacturing KPI Key Performance Indicator QC Quality Control QA Quality Assurance DT Down Time CM Corrective Maintenance PM Preventive Maitenance HSE Health Safety Enviroment iv LIST OF TABLE Table 2.1: Classification of Losses .1: OEE index of MSE1, MSE2, and MSE3 in 2022 .3: Top 20 of Repeated Machine Failures .4: Top 10 Name of machine failures .1: Project role of members. 43 v LIST OF FIGURES Figure 1.1: Logo of Bosch Vietnam Co.2: Factual information and statistics about Bosch in Vietnam in 2022 .3: Factual information and statistics about Bosch in Vietnam in 2021 .4: Some of Bosch's brands .5: Bosch Long Thanh Plant .6: Products of the company (CVT Push Belt) .8: Organization chart of TEF department .1: Eight-pillar approach for TPM implementation .2: 7 steps in autonomous maintenance .3: 16 losses in TPM .4: 6 steps of planned maintenace implementation .1: Maintenance method in 2022 .1: Detailed implementation plan .3: AM standard creating and removing procedure .4: Main items in Manual Master software .5: Bosch Tube display .6: AM document storing before and after applying digitalization .7: Webform of PM – AM Work instructions .8: Webform of CM – AM Work instructions .9: Operators are trained in preventive maintenance practice at Element Hardening line 4 .10: Trainer instructs repairs at Fine Blanking line 7 .11: OEE Before and After applying digitalization in AM. 62 vi TABLE OF CONTENTS COMMENTS OF ADVISOR.i COMMENTS OF REVIEWER. iii LIST OF ABBREVIATION.iv LIST OF TABLE.
v LIST OF FIGURES .vi TABLE OF CONTENTS. vii INTRODUCTION TO THE REPORT. Scope and object. Structure of report.
4 CHAPTER 1: INTRODUCTION ABOUT BOSCH VIETNAM CO.1 Introduction about Bosch Vietnam Co.1 History of formation and development of the Bosch Group .2 About Bosch Brand .3 Bosch Powertrain Solutions plant in Dong Nai .2 Organization chart of HcP .1 Overview HcP’s Department .2 Organization chart of technical functions department. 14 CHAPTER 2: LITERATURE REVIEW.1 Literature review of digitalization .1 The concept of digitalization .2 The need for digitalization in maintenance .2 Literature review Total productive maintenance. 22 CHAPTER 3: ANALYSIS OF THE STATUS OF TOTAL PRODUCTIVE MAINTENANCE IMPLEMENTATION AT BOSCH VIET NAM .2 Overview Bosch’s Maintenance Methods .3 Overview the current status of TPM at Bosch Viet Nam .1 Overall Equipment Effectiveness .2 Mean time between failure (MTBF) .3 Frequency of machine breakdowns and repeated failures. Assess the current status of TPM Effectiveness .1 Strength of current TPM .2 Limitations of current TPM.
42 CHAPTER 4: APPLY THE DIGITALIZATION INTO AUTONOMOUS MAINTENANCE IMPLEMENTING TO ENHANCE THE TOTAL PRODUCTIVE MAINTENANCE EFFECTIVENESS: A CASE OF BOSCH VIET NAM.1 Project Initiation and Planning .1 Role of members .2 AM procedure to add-in or remove AM standard: .3 Introduction AM controlling on Manual Master Software .1 Manual Master Main Page Introduction .2 AM Work Instruction Webform Format .3 Training Operator for doing Autonomous Maintenance activities .3 Benefits of the project .1 Develop a application for the TPM Management. 66 viii INTRODUCTION TO THE REPORT 1. Rationale In an ever-changing and competitive world, companies are constantly challenged by shifts in the market, technology, environment, and economy. To stay ahead, companies must adapt by adopting new strategies and being open to continuous learning.
Traditional maintenance, once seen as just a remedy for breakdowns, has evolved into a crucial strategy for improving company operations and competitiveness. The Maintenance Function now focuses on ensuring efficient operations and collaboration between departments. Within this context, Total Productive Maintenance (TPM) emerges as a method to enhance production efficiency and reduce issues. TPM can help companies save costs, offer better pricing, and deliver faster to their customers, making them more competitive.
Meanwhile, in the Industry 4.0 era, focusing on data is essential. This data guides company decisions and strategies.0 technologies allows companies to monitor their operations closely and eventually evolve into smart factories. For many years, Bosch Viet Nam has been recognized as a reputable manufacturer of CVT push belts. This respect and trust come not only from their commitment to quality but also from their association with top automobile brands worldwide.
One of the major contributors to their consistent quality is the Total Productive Maintenance (TPM) approach. What sets Bosch Viet Nam's TPM apart is their integration of advanced digital systems, elevating their productivity management to higher standards. The document management software from ManualMaster has smart features that help you keep track of everything and make sure that the right people can get the right information at the right time. You make things more efficient, lower a lot of risks, and give people more freedom and responsibility.
A business has to deal with tens, hundreds, or even thousands of papers, process diagrams, and forms, so it's important to have good document management. Even more so if standards for quality are also set for this information. In addition to its significant 1 contribution to production and quality management, the Manual master system at Bosch assumes a crucial role by providing all associates with standardized digital work instructions for various tasks. The utilization of this method has the potential to enhance productivity.
However, the current approach does not account for maintenance operations, which often contribute to breakdowns due to the operator's inability to promptly and accurately address basic machine damages. These maintenance activities mostly rely on the expertise of maintenance engineers, Along with providing an operator who is able to repair certain typical machine damage, integrating the manual master system into documenting work instructions will make it easier for them to access any methods of fixing and will help them reply more quickly. The author intends to conduct a project aimed at enhancing the Autonomous Maintenance pillar of Total Productive Maintenance (TPM) by the use of digitalization. the author has chosen the topic “Applying digitalization to enhance the effectiveness of Total Productive Maintenance (TPM): A case study of Bosch Vietnam” In order to enhance the occurrence of breakdowns resulting from common machine damage during operational activities, it is imperative to suggest suitable digitization strategies that can effectively enhance work efficiency and reduce the extent of excessive workload for maintenance engineers, that makes the TPM at Bosch more effective.
Objectives - The author has raised concerns regarding maintenance activities, specifically pertaining to the preservation of crucial work instruction documents inside the TEF department of the TPM and Methods department at Bosch Vietnam Co. - This proposal aims to address the need for digitization and the subsequent implementation of digitization solutions inside the document management system at the TEF department. By doing so, it is anticipated that the efficiency of maintenance activities will be enhanced. 2 - The objective is to create an accessible application that integrates all TPM informations, thereby establishing a centralized platform for all stakeholders to access, resulting in enhanced productivity.
- Improve document control through the implementation of a centralized and standardized Manual master system, which will facilitate convenient access, improve organizational efficiency, and ensure the secure management of data. - The assessment of the efficacy of the implementation process and the outcomes attained. Scope and object - Scope: Scope of space: TEF Department - Bosch Long Thanh Factory - Bosch Vietnam, Co. Scope of time: Analyze the current situation of operations at the TEF department from 2022 to 2023.
- Object: The Total productive maintenance in TEF department at the Bosch Vietnam Co. Research methodology Using secondary documents and reports from the TEF department during the years 2022 and 2023 to determine the reason that is affecting the rising amount of downtime and will contribute to strengthening the operator awareness skills of the organization in the future. The strategy that makes use of secondary documents will make it much simpler to collect information, and the papers that are now available are saved in the document directory of the TEF department. The data that was updated and recorded in the years 2022 and 2023 will accurately reflect the current situation regarding the productivity of equipment and production losses.
In the meantime, make use of quality control tools like survey forms, fishbone diagrams, and Pareto charts to collect data in order to discover the primary source of the problem and, as a result, offer remedies that will help 3 increase the factory workers' ability to do autonomous maintenance. In addition, the author incorporates both interviews and conversations with maintenance engineers into his discussion of the current state of training for rectifying typical faults in machine operation for manufacturing operators. Consequently, this will lead to an improvement in the performance of maintenance at the Total Productive Maintenance and method department. Structure of report The report consists of four chapters, specifically: - Chapter 1: Introduction about Bosch Vietnam Co.
- Chapter 2: Literature review. - Chapter 3: Analysis of the status of maintenance at Total Productive maintenace and method department. - Chapter 4: Applying the digitalization into Autonomous maintenance pillar of TPM in TEF department. - Conclusion 4 CHAPTER 1: INTRODUCTION ABOUT BOSCH VIETNAM CO.1: Logo of Bosch Vietnam Co., Ltd Source: Company Website 1.1 Introduction about Bosch Vietnam Co., Ltd The Bosch Group is a well-known provider of technology and services on a global scale.
It employs roughly 421,000 associates worldwide (as of December 31, 2022). Manufacturing and industrial technologies are at the core of the company's business.