An investigation into current production challenges facing the Libyan cement industry and the need for innovative total productive maintenance (TPM) strategy

Abstract

PurposeThe purpose of this paper is to investigate maintenance and production problems in the cement industry in Libya, with particular emphasis on future implementation of total productive maintenance (TPM).Design/methodology/approachThe paper presents the use of case study approach of production data and history, field visits, a survey methodology using a detailed questionnaire with employees and interviews with top and middle managers in four cement factories.FindingsIt has been found that the four factories under investigation have low productivity and production levels when compared with the design values. There is no clear TPM strategy and also it has been found that the lack of training and personal development is the main cause of this problem. In addition, employees are found not to be motivated as a result of the lack of a management strategy and reward structure.Research limitations/implicationsBased on the findings, a new framework for TPM has been developed. This TPM strategy could be implemented in other Libyan factories as a result of the potential similarities in the cultural and environmental aspects.Practical implicationsThe current challenges have been identified and comparative analysis is developed into a model for the implementation of TPM.Originality/valueThe paper highlights limitations in some of the cement factories in Libya in relation to TPM and production strategies. The importance of adopting a realistic strategy and framework by managers is discussed. This work is developed as collaboration between academia and one of the Libyan cement companies to solve productivity problems and develop a strategic framework of TPM for improving Libyan industry.