Application of Total Productive Maintenance and Overall Equipment Effectiveness in Improving Ampoule Filling Machine Performance

PurposeThis research aims to investigate critical success factors, barriers and initiatives of total productive maintenance (TPM) implementation in selected manufacturing industries in Addis Ababa, Ethiopia.Design/methodology/approachThis study built and looked into a conceptual research framework. The potential barriers and success factors to TPM implementation have been highlighted. The primary study techniques used to collect relevant data were a closed-ended questionnaire and semi-structured interview questions. With the use of SPSS version 23 and SmartPLS 3.0 software, the data were examined using descriptive statistics and the inferential Partial Least Square Structural Equation Modeling (PLS-SEM) techniques.FindingsAccording to the results of descriptive statistics and multivariate analysis using PLS-SEM, the case manufacturing industries' TPM implementation initiative is in its infancy; break down maintenance is the most widely used maintenance policy; top managers are not dedicated to the implementation of TPM; and there are TPM pillars that have been weakly and strongly addressed by the case manufacturing companies.Research limitations/implicationsThe small sample size is a limitation to this study. It is therefore challenging to extrapolate the research findings to other industries. The only manufacturing KPI utilized in this study is overall equipment effectiveness (OEE). It is possible to add more parameters to the manufacturing performance measurement KPI. The relationships between TPM and other lean production methods may differ from those observed in this cross-sectional study. Longitudinal experimental studies and in-depth analyses of TPM implementations may shed further light on this.Practical implicationsDefining crucial success factors and barriers to TPM adoption, as well as identifying the weak and strong TPM pillars, will help companies in allocating their scarce resources exclusively to the most important areas. TPM is not a quick solution. It necessitates a change in both the company's and employees' attitude and their values, which takes time to bring about. Hence, it entails a long-term planning. The commitment of top managers is very important in the initiatives of TPM implementation.Originality/valueThis study is unique in that, it uses a new conceptual research model and the PLS-SEM technique to analyze relationships between TPM pillars and OEE in depth.

The Overall Equipment Effectiveness (OEE) is an established method to monitor and improve the effectiveness of manufacturing processes. OEE is frequently used as a key metric in Total Productive Maintenance (TPM) and Lean Manufacturing environment. This paper focuses on the OEE measurement of the assembly line of steering gear in an automotive company (AGR Sdn Bhd) through the implementation of TPM. The average OEE measurement before implementation of TPM is 52.21% which is below the company’s target. The company used reactive maintenance, which is inherently “wasteful and ineffective. After the implementation of TPM, the OEE performance for the assembly department improved to 70.21%. The result shows that machine down time directly influence the OEE. The implementation of TPM enables the company to change their maintenance practices from reactive to proactive. The average availability percentage is 80.34% and performance efficiency average is 87.99%. This has directly contributed to a lower overall OEE performance compared to world standard. The rate of quality is maintained at an average of 99.54%.

Today competitive manufacturing requires innovative approaches in the production management, as well as for customer satisfaction. Production management requires an effective and efficient maintenance management system. One approach to improve the performance of the maintenance system is through the implementation of Total Productive Maintenance (TPM). The key performance index to measure the effectiveness of TPM implementation is Overall Equipment Effectiveness (OEE). The TPM activities will eliminate equipment losses related to availability, performance rate, and quality rate. Hence, the TPM implementation will increase the OEE value. This paper outlines the theories of TPM and OEE. The paper also presents the studies carried out by different authors to show the improvement of OEE through implementation of TPM in manufacturing, such as electronic industry, steel manufacturer, as well as locomotive components manufacturer.

The application of Total Productive Maintenance (TPM) using the Overall Equipment Effectiveness (OEE) method at PT. DEF, The issue of maintenance has become crucial as it affects not only the reliability of the machines but also the speed and quality of production. This study will explore how the implementation of TPM using the OEE approach can improve machine effectiveness in a production environment, with a focus on timely and optimal maintenance strategies.The research aimed to assess the efficiency and effectiveness of machine operations, particularly injection molding machines, within the company's production line. Through the collection and processing of operational data, it was found that the OEE value for the machines in question ranged from 94% to 95%, surpassing the company's set standard of 93%. The high OEE score reflects effective machine utilization, availability, performance, and quality rates. The research highlights that while the current system meets international standards for machine maintenance, continuous improvements can further optimize machine productivity and reduce downtime. Keywords: Injection, Molding, OEE, TPM

Nowadays, consumers expect manufacturers to provide excellent quality, reliable delivery and competitive pricing. This demands that the manufacturer's machines and processes are highly reliable. In order to possess highly reliable machines to make sure smooth manufacturing process, many organizations have implemented Total Productive Maintenance (TPM) as the enabling tool to maximize the effectiveness of equipment by setting and maintaining the optimum relationship between people and their machines. Overall Equipment Effectiveness (OEE) is used as a measure when evaluating the result of TPM. This paper intends to find out the difference between before and after the TPM implementation to OEE result. Comparison between before and after the implementation of TPM is carried out to see the difference that TPM can bring to an organization. Elements that constitute the OEE equation will be analyzed in order to identify which one that affects OEE result. After identifying, improvement will be made on that element so that OEE result will be improved ultimately. The approach used in this paper is experimental and the instruments used to collect data are observation and interview. Microsoft Excel is used to analyze data obtained and calculate OEE. Hence, TPM is a useful tool in helping firm to achieve optimal manufacturing process. By being able to achieve this level of maintenance, an organization will be able to reap competitive advantages brought by TPM, thus, producing quality products that manage to satisfy customers and subsequently generating greater profits.

Total productive maintenance (TPM) is a method to improve and enhance productivity. TPM permanently improves the overall effectiveness of equipment, with the active involvement of operators. This paper describes the pilot implementation and evaluation of TPM for the dental units in the Dental Hospital, Faculty of Dentistry, Chiang Mai University, Thailand. The paper aims to develop a methodology for increasing the dental unit utilization and availability, as well as decreasing unplanned equipment downtime. The methodology was developed based on the first two phases of the phased equipment management approach; improvement of existing equipment and maintaining improved equipment. Both autonomous maintenance (AM) by operators and preventive maintenance (PM) were implemented. Documents such as PM manual, procedures and forms were developed. Both quantitative and qualitative research methods were used to evaluate the performance of the implemented maintenance program. The experiences from this will be useful for other healthcare organizations that would like to implement TPM. Furthermore, through a pilot study of implementing TPM in a dental hospital, the practical aspects within and beyond basic TPM theory, difficulties in the adoption of TPM and the problems encountered during the implementation are discussed.

In the manufacturing process, the machine is very important because downtime can inhibit and even stop production. We focused on the highest downtime that occurred in a particular product line and critical machine. This research contributes to overcoming and making the machine's performance and ability better. We make use the Total Productive Maintenance (TPM), which started by calculating Overall Equipment Effectiveness (OEE) and Six Big Losses. This study also provides the maintenance attempt to increase the effectiveness and to eliminate losses incurred by calculating Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR). Finally, we proposed the TPM implementation to improve the effectiveness of the machine. The result showed that the OEE has not reached the ideal value due to the low availability. Breakdown losses contributed to the biggest factor in the loss. The way to overcome the cause of breakdown losses is to increase performance maintenance, by calculating and evaluating MTBF and MTTR. This research presented the cause of the low value of OEE, provided the performance maintenance policy according to MTBF and MTTR, and proposed the TPM implementation.

The study aimed to assess the efficacy of HPLC instruments in a pharmaceutical laboratory at PT. XYZ by evaluating three OEE matrices (availability, performance, and quality) and identifying the losses leading to low OEE scores affecting the chromatography process performance. The method used is quantitative to calculate the availability rate, performance rate, and quality ratio based on the breakdown data and quantity of product data, followed by calculating the OEE score and comparing the obtained OEE and the world-class standard OEE score. The results demonstrate that the average availability rate in 2022 is 90,73%, the performance rate is 90,45%, and the quality ratio is 95,55%, resulting in the OEE score of 78,42%, which does not meet the world-class OEE standards score. To identify the problems causing the low OEE score, a qualitative analysis is performed using Current Condition Analysis and Fish Bone Diagram. Research indicates that five factors contribute to low OEE scores for HPLC instruments in PT. XYZ, including Method, Man, Machine, Material, and Environment. For each factor, the proposed improvement is described to increase the OEE score, including establishing the maintenance procedure, a training program for laboratory personnel, inventory management for spare parts, and an operating procedure. Keywords: Total Productive Maintenance, Overall Equipment Effectiveness, HPLC, Fish Bone Diagram

This paper explains the Total Productive Maintenance (TPM) concepts and the interrelationship existing between TPM, Total Quality Management (TQM) and Lean manufacturing. It also explains various pillars of TPM and significance of each pillar in TPM implementation. Here an attempt was made to discuss the previous literature related to TPM. This review was based on a wide range of journals published in last 15 years, specifically related to TPM and its implementation in manufacturing industries. It explains how TPM can be effectively implemented in improving productivity, profitability and Overall Equipment Effectiveness (OEE) in any manufacturing industry. Most of the literature discusses the OEE improvement which is found to be the main objective of TPM implementation. The paper also explains computation of OEE, major losses associated with it and stages in TPM introduction. In the final sections of this paper, obstacles that hamper successful TPM implementation and gaps in implementing TPM in Indian industries are discussed.

PT XYZ is one of the companies engaged in the precast concrete manufacturing industry which is specially designed to meet the needs of industrial markets such as high-quality building and building construction. The machine under study is the machine used for assembling the spun pile reinforcement frame in the rotary workshop. The purpose of this study is to analyze the application of Total Productive Maintenance (TPM) through the effectiveness and efficiency of heading machine performance and analyze the factors that affect the Overall Equipment Effectiveness (OEE) value and present a proposed heading machine maintenance strategy. The method used is OEE with Six Big Losses analysis. For the analysis of the six big losses on the OEE value, namely the value of Idle and minor stoppage (a decrease due to many machine stops) which is a factor that has the largest percentage of the six big losses with a resulting factor value of 7.0%. Then followed by reduced speed losses (decrease in engine speed) of 3.96% and then deffect losses of 3.48% and the three other factor values, namely breakdown losses, setup losses, and yield losses. Measurement of the level of effectiveness and efficiency of the heading machine at PT XYZ using the OEE method for the period 2022 in January - December obtained an average value of 78.28%. The resulting value is still far from the ideal OEE standard value of 85% which refers to the world class standard. The lowest OEE factor value is obtained from the calculation of Performance Efficiency of 86.29% where it is necessary to update the machine maintenance scheduling so as to increase the efficiency of the heading machine performance that supports the production speed of the company.

Nowadays, consumers expect manufacturers to provide excellent quality, reliable delivery and competitive pricing. This demands that the manufacturer's machines and processes are highly reliable. In order to possess highly reliable machines to make sure smooth manufacturing process, many organizations have implemented Total Productive Maintenance (TPM) as the enabling tool to maximize the effectiveness of equipment. Overall Equipment Effectiveness (OEE) is used as a measure when evaluating the result of TPM. This paper has found out the difference between before and after the TPM implementation to OEE result. Comparison between before and after the implementation of TPM was carried out to see the difference that TPM can bring to an organization. Elements that constitute the OEE equation have been analyzed and indentified which one that affected OEE result. After identifying, improvement has been made on that element so that OEE result would be improved ultimately. Microsoft Excel was used to analyze data obtained and calculate OEE. Hence, TPM is a useful tool in helping firm to achieve optimal manufacturing process. By being able to achieve this level of maintenance, an organization will be able to reap competitive advantages brought by TPM, thus, producing quality products that manage to satisfy customers and subsequently generating greater profits.

Purpose: This study looks at both the visible and less obvious benefits of implementing TPM, exploring its impact on costs and operations in modern industrial supply chains. The scope of this work was done with, but not limited to Manufacturing companies, Food and Beverage companies, CPGs and similar large and small scale consumer-facing multinationals. While the tangible benefits of TPM such as reduced downtime, fewer breakdowns, and lower maintenance costs are well-known, the study also highlights important intangible gains. These include enhanced employee morale, reduced turnover, and stronger teamwork. By involving employees in maintenance, TPM gives them a sense of ownership and pride in their work, which leads to greater job satisfaction and better overall performance. Materials and Methods: Using a mixed-methods approach, the research combines interviews with industry professionals and quantitative data from organizations that have adopted TPM. Insights from plant managers, maintenance staff, and other stakeholders provide valuable context, while key performance metrics such as Overall Equipment Effectiveness (OEE), Mean Time between Failures (MTBF), and Mean Time to Repair (MTTR) quantify the improvements in equipment reliability and productivity achieved through TPM. Finding: The findings show that TPM enhances OEE by improving equipment availability, performance, and quality. Organizations that implement TPM experience fewer unplanned breakdowns and stoppages, which results in better resource utilization, higher production rates, and greater profitability. By encouraging proactive maintenance, TPM helps employees catch minor issues before they turn into costly problems. Another important benefit of TPM is the positive impact on employee involvement and satisfaction. Involving employees at all levels in maintenance tasks creates a team-oriented culture that boosts engagement. Research suggests that engaged employees show higher productivity, better work quality, and lower absenteeism and turnover. With more reliable equipment, companies can deliver higher-quality products, avoid delays, and improve customer satisfaction. Unique Contribution to Theory, Practice and Policy: The study concludes that TPM should be viewed as a long-term strategic initiative. Expanding TPM practices beyond production to include areas like logistics, human resources, and administration could help drive a broader cultural shift. Overcoming resistance to change is crucial for TPM’s success, and incorporating Industry 4.0 technologies such as predictive maintenance, IoT sensors, and machine learning can further optimize maintenance, prevent breakdowns, and enhance TPM’s effectiveness. In short, TPM is not just a tool for improving equipment and operational efficiency; it also strengthens organizational culture, boosts employee morale, and enhances customer satisfaction. By integrating TPM with advanced technologies, companies can position themselves for sustainable success in the ever-evolving industrial landscape.

Purpose The purpose of this paper is to review the literature on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices adopted by the manufacturing organizations. It also seeks to highlight appropriate enablers and success factors for eliminating barriers in successful TPM implementation. Design/methodology/approach The paper systematically categorizes the published literature and then analyzes and reviews it methodically. Findings The paper reveals the important issues in Total Productive Maintenance ranging from maintenance techniques, framework of TPM, overall equipment effectiveness (OEE), TPM implementation practices, barriers and success factors in TPM implementation, etc. The contributions of strategic TPM programmes towards improving manufacturing competencies of the organizations have also been highlighted here. Practical implications The literature on classification of Total Productive Maintenance has so far been very limited. The paper reviews a large number of papers in this field and presents the overview of various TPM implementation practices demonstrated by manufacturing organizations globally. It also highlights the approaches suggested by various researchers and practitioners and critically evaluates the reasons behind failure of TPM programmes in the organizations. Further, the enablers and success factors for TPM implementation have also been highlighted for ensuring smooth and effective TPM implementation in the organizations. Originality/value The paper contains a comprehensive listing of publications on the field in question and their classification according to various attributes. It will be useful to researchers, maintenance professionals and others concerned with maintenance to understand the significance of TPM.

<div><p><em>This study aims to examine and analyze the impact of work attitude, Total Productive Maintenance (TPM) on the Overall Equipment Effectiveness (OEE) and production continuity and the other effect of Work Attitude and Total Productive Maintenance (TPM) on production continuity: The mediating role of Overall Equipment Effectiveness (OEE). The research was conducted at PT. Semen Tonasa i.e. units II to V unit which is the largest cement producer in eastern Indonesia. Withdrawal of respondents did with the criteria that only respondents yang having their respective sectors and who have work experience of at least one year were used as samples. Results of analysis Partial Least Square (PLS) Version 2.0.M3 used in analyzing the contribution of exogenous variables on endogenous variables directly, Sobel Test was used for pushing analyze the contribution of the indirect effect (mediation) whereas importance- performance analysis (IPA) to analogous interpret the relationship loading factor value and the average value. The results of this study provide evidence of work attitude has a positive and significant effect on the overall equipment effectiveness (OEE), total productive maintenance (TPM) has a positive and significant effect on overall equipment effectiveness (OEE), work attitude, total productive maintenance (TPM) and overall equipment effectiveness (OEE) positive and significant impact on production continuity.</em></p></div>

This study aims to examine and analyze the impact of work attitude, Total Productive Maintenance (TPM) on the Overall Equipment Effectiveness (OEE) and production continuity and the other effect of Work Attitude and Total Productive Maintenance (TPM) on production continuity: The mediating role of Overall Equipment Effectiveness (OEE). The research was conducted at PT. Semen Tonasa i.e. units II to V unit which is the largest cement producer in eastern Indonesia. Withdrawal of respondents did with the criteria that only respondents yang having their respective sectors and who have work experience of at least one year were used as samples. Results of analysis Partial Least Square (PLS) Version 2.0.M3 used in analyzing the contribution of exogenous variables on endogenous variables directly, Sobel Test was used for pushing analyze the contribution of the indirect effect (mediation) whereas importance- performance analysis (IPA) to analogous interpret the relationship loading factor value and the average value. The results of this study provide evidence of work attitude has a positive and significant effect on the overall equipment effectiveness (OEE), total productive maintenance (TPM) has a positive and significant effect on overall equipment effectiveness (OEE), work attitude, total productive maintenance (TPM) and overall equipment effectiveness (OEE) positive and significant impact on production continuity