An evaluation of TPM implementation initiatives in an Indian manufacturing enterprise

Abstract

PurposeThe purpose of this study is to identify maintenance‐related losses for ascertaining and addressing the performance losses, and affecting improvements in the manufacturing performance in an organization through strategic total productive maintenance (TPM) initiatives.Design/methodology/approachIn this paper TPM initiatives in the steel manufacturing plant have been elaborated to ascertain the tangible and intangible benefits accrued as a result of successful TPM implementation. The approach has been directed toward justification of TPM implementation for its support to competitive manufacturing in the context of Indian manufacturing industries.FindingsThe paper establishes the long‐term effects of TPM on organizational performance in the Indian context. TPM implementation initiatives have shown marked improvements in the equipment efficiency and effectiveness, and have also brought about appreciable improvements in other manufacturing functions in the organization. It has been observed that systematic interventions regarding TPM deployment have significantly contributed toward improving the manufacturing system productivity, quality, safety, morale and besides ensuring the cost effectiveness of the manufacturing function within the organization. The case study reveals that holistic TPM implementation has lead to establishment of strategic proactive maintenance practices in the organization for avoiding future system and equipment‐related losses, and has marshaled the organization toward capability building for sustained competitiveness in the global marketplace.Practical implicationsThis paper highlights the contributions of maintenance function to ensure enhanced equipment reliability, thereby affecting improvements in the manufacturing system performance. In this study the TPM implications in a steel manufacturing plant have been highlighted, which may be implemented in other manufacturing plants to improve their performance.Originality/valueThe present study encompasses systematic identification of maintenance‐related losses, setting up of targets regarding maintenance performance improvements and developing guidelines for achieving enhanced manufacturing system performance through strategic TPM initiatives in the steel manufacturing plant, which can also be important to all concerned with maintenance and safety in various manufacturing enterprises.