Enhancing Overall Equipment Effectiveness Through Total Productive Maintenance And Root Cause Analysis: A Case Study On Melka Wakena Hydroelectric Power Plant

Abstract

Equipment Effectiveness Is A Critical Performance Evaluation Standard Used In Industries With High Asset-Overall Based Operations To Quantify The Degree To Which Equipment Is Utilized. In Hydroelectric Power Plants, Overall Equipment Effectiveness Is Vital, As Availability, Performance, And Reliability Of Generation Units Have Direct Effects On Generation Of Power, Plant Efficiency, And National Energy Production. The Aim Of This Study Is To Enhance Overall Equipment Effectiveness At Melka Wakena Hydroelectric Power Plant By Using Total Productive Maintenance And Root Cause Analysis. The Study Addressed Major Maintenance Related Issues, Including Frequent Machine Breakdowns, And A Lack Of Synergy Between Production And Maintenance Management. Through A Comprehensive Analysis Involving Observation Of The Production Process, Historical Data Collection, Real-Time Monitoring, Interviews With Plant Personnel And Questionnaires For Managers, Maintenance Personnel, And Operators For Data Collection. The Research Evaluated The Impact Of Total Productive Maintenance And Root Cause Analysis On Overall Equipment Effectiveness By Partial Least Square Structural Equation Modeling (Pls-Sem), Equipment Downtime, Performance Efficiency, Operational Reliability, And Safety Standards. The Study Also Identified The Root Cause Of Low Overall Equipment Effectiveness And Frequent Causes Of Machine Failures Through Root Cause Analysis Tools, The Fish bone Diagram Along With The 5 Whys Technique And Using The Pareto Chart The Major Contributor To The Problem Was Determined. From The Study, The Oee Of The Power Plant Working Units Was Found 55% Which Is The Lowest Value Compared With The World-Class 85 % Oee. The Results Proved That Total Productive Maintenance And Root Cause Analysis Have A Significant Impact On The Improvement Of The Overall Equipment Effectiveness Of The Case Power Plant And The Suggested Solution Provided For The Identified Problems Through Root Cause Analysis. This Research Assessed The Strategic Importance Of Total Productive Maintenance In Improving The Energy Production And Operational Efficiency In The Hydroelectric Power Plant.