Total Productive Maintenance Implementation Research Articles

Herramientas de Gestión para la Optimización del Minado Subterráneo

The objective of this research work was to optimize productivity and reduce costs in mechanized underground mining operations; for which management tools such as TPM (Total Productive Maintenance) were applied, which made it possible to ensure the expected reliability of the equipment and Management Indicators (KPIs), contributing to greater effectiveness in operations and statistical tools to improve quality, Pareto charts and Ishikawa diagrams. A descriptive methodology consisting of the daily collection of data contained in the mine operations records, to analyze it and identify opportunities for improvement in each process, thus determining unproductive delays in drilling, ore cleaning and hauling. Among the results, it was identified that the availability of the H 357 drilling equipment had an increase of 6.80% after implementing management tools. It was also evident that productivity increased considerably in the effective working time of the Scoop measured in tons/hour, thanks to the implementation of TPM, from 79.90 to 85. Ultimately, the application of management tools allowed a philosophical change within the organization, guiding a more effective management of operations of the mining company.

Analisis Produktivitas pada Mesin BM 206 D-2 Menggunakan Metode Total Productive Maintenanace (TPM) dengan Pendekatan Overall Equipment Efectiveness (OEE) di PT. Berlina Tbk

Productivity is key to success in the manufacturing industry, particularly at PT.BERLINA Tbk, which specializes in plastic packaging manufacturing. This study focuses on enhancing the operational effectiveness of the BM 206 D-2 machine trough the implementation of Total Productive Maintenance (TPM) and measurement of Overall Equipment Effectiveness (OEE) as well as the identification and mitigation of Six Big Losses. The research involves two sampling periods, each spanning two quarters. During the first period, the average OEE value of 66% indicated that the greatest losses were due to machine breakdown or Breakwon Losses, related to deficiencies in operator and technician skills, inadequate planes maintenance, and machine cleanliness. Following the implementation of improvements based on these findings, the average OEE incrased to 71% in the second period. These results underscore the importance of enhancing technical skills, effective maintenance, and strict cleanliness to improve productivity and reduce production losses.

Analysis of Cut Size Paper Cutting Machine Performance Using Total Productive Maintenance Concept (Case Study: PT. RST)

PT. RST, a leading paper factory in Indonesia, prioritizes timely production by optimizing productivity, efficiency, and paper quality. This study assesses the reliability of the Cut Size (CS) paper cutting machine, which is enhanced through the implementation of Total Productive Maintenance (TPM) as a management philosophy to ensure high-efficiency operations. To evaluate machine performance, Overall Equipment Effectiveness (OEE) measurement is used. From data collected from January to September 2023, an analysis is conducted to improve the performance of the CS machine, which has not met its set target. The average OEE value of 70.9% falls short of the target of 72%. This research aims to improve the performance of the CS machine through the TPM approach, focusing on the Focused Maintenance pillar. Using tools such as Pareto diagram, why-why analysis, fishbone diagram, and the 5W1H method, several sources of problems causing the decrease in OEE value will be identified and addressed.

Measuring total productive maintenance success: a new industrial evaluation using fuzzy SERVQUAL

ABSTRACT In today’s competitive business landscape, maintaining market position and customer satisfaction relies on high-quality equipment maintenance. Total Productive Maintenance (TPM) is a popular method for optimizing internal efficiency. However, despite its popularity, companies still face challenges in implementing TPM. This study proposes a comprehensive evaluation model combining SERVQUAL and fuzzy set theory (Fuzzy SERVQUAL) to assess TPM implementation and identify obstacles for focused strategies. The results demonstrated that the level of implementation within the Moroccan industrial sector ranges from 3 to 4, as per the Classic SERVQUAL, showing a minimum level between 2 and 3 and a maximum level between 4 and 5 based on the nuanced analysis of Fuzzy SERVQUAL. The success of TPM implementation in the industrial sector is largely attributed to the human element, which includes prioritizing employee attention, enhancing skills, and which involves prioritizing employee attention, skill enhancement, and active involvement in decision-making processes.

Implementation of Total Productive Maintenance on Frame Welding Machine Maintenance Using the Overall Equipment Effectiveness (OEE) Method at PT Electronics Components Indonesia

PT. Electronics Components Indonesia manufactures capacitors and focuses on enhancing productivity and operational efficiency of the frame welding machines through effective maintenance. This study employs a quantitative method to analyze the Overall Equipment Effectiveness (OEE) values, including availability, performance efficiency, and rate of quality, as well as conducting a Six Big Losses analysis. The results indicate that the average availability reached 97.83%, with a significant decrease in August due to downtime. Performance efficiency remained consistently above 90%, although higher product output tended to reduce efficiency. The rate of quality was stable and high, reflecting improvements in production processes and quality control. The average OEE value reached 88%, exceeding the global standard of 85%. To further enhance the effectiveness of the frame welding machines, suggested improvements include operator training, regular performance evaluations, attention to operator well-being, selection of high-quality raw materials, updating SOPs, regular preventive maintenance, improving workplace safety, and investing in backup energy systems. In conclusion, the improvements implemented successfully enhanced the performance and operational quality of the frame welding machines.

Implementation of Total Productive Maintenance (TPM) Using Overall Equipment Effectiveness (OEE) Method on HPLC Instruments in Laboratory

Implementation of Total Productive Maintenance (TPM) Using Overall Equipment Effectiveness (OEE) Method on HPLC Instruments in Laboratory

A REVIEW ON TOTAL PRODUCTIVE MAINTENANCE (TPM)

Total Productive Maintenance (TPM) is transforming manufacturing landscapes. This review investigates its impact, revealing how TPM fosters a culture of continuous improvement through employee involvement and proactive maintenance strategies. By analyzing 30 research papers, it unveils the potent link between TPM and increased productivity alongside reduced waste. Highlighting Overall Equipment Effectiveness (OEE) as a crucial metric, the review emphasizes the importance of 5S as a foundational step for successful TPM implementation. With global adoption surging, TPM is solidifying its position as a world-class strategy for achieving peak manufacturing performance." Keywords: Total Productive Maintenance (TPM), OEE, Improve Productivity, 5S.

Facing Challenges of Implementing Total Productive Management and Lean Tools in Manufacturing Enterprises

Manufacturing companies are always looking for ways to outperform their competitors. They are constantly trying to improve their efficiency and reduce costs. One method that improves efficiency and maximises the availability of production equipment is total productive maintenance (TPM), which is a lean optimisation philosophy tool that focuses on the optimisation of maintenance. Although TPM is known for improving maintenance, there are many obstacles to its successful implementation. Failure to properly implement TPM can result in additional costs and lost time, and it can have a negative impact on employees. For these reasons, a survey was prepared and conducted among several companies, each involved in a different field of work and having a different number of employees. The main findings of this research are the key factors that can negatively impact the implementation of TPM and lean tools in general, as well as suggestions for improvements that can ensure their successful implementation and sustainability. An analysis was conducted based on the size of each company as well as the job roles within them. The study covers issues that may arise during the implementation of TPM and other lean tools at all levels of the hierarchy in an enterprise and provides guidance on how to manage situations that may prevent the successful application of TPM.

Implementation and Improvement of the Total Productive Maintenance Concept in an Organization

Total Productive Maintenance (TPM) is an infrastructure-managing methodology that leads to improvements in production efficiency, quality, and safety. It includes a set of processes, techniques, and strategies based on forecasting, maintenance, the optimized cooperation of different company departments, and the minimization of costs related to downtime or accidents caused by equipment failure. This article discusses the history, assumptions of the TPM concept, and approach to implementing Total Productive Maintenance in organizations in detail. The right ingredients required for successful TPM implementation and barriers to implementation are also reviewed. The benefits of implementing TPM in organizations are presented and supported with examples of implementations in production and non-production organizations. The article is addressed to representatives of the manufacturing industry. TPM also indicates a high potential for implementation in non-production areas, which may be interesting, for example, for the service, medical, or laboratory industries.

Analysis of Effectiveness of Cut Size Line Machines Based on Total Productive Maintenance (TPM) and Analytical Hierarchy Process (AHP) - A Case Study

This research aims to analyze the implementation of Total Productive Maintenance (TPM) using Overall Equipment Effectiveness (OEE) and Analytical Hierarchy Process (AHP) approaches to increase the OEE value on cut-size line machines in the finishing department in PT. X. The research methodology was carried out by calculating OEE and significant loss values, analyzing Pareto and Fishbone diagrams, and using the AHP as a decision-making method. Then, the recommendations for implementing focused and autonomous maintenance in the case study company. The research results revealed that the significant influencing factor for the OEE value was engine speed, which causes performance efficiency to decrease so that the OEE value also decreases. The OEE value in 2021 is 74%. The improvement plan by applying the TPM and AHP methods will be expected to increase the performance efficiency of the machine via OEE value from 74% in 2021 to 79% for the coming year 2023/2024.

Evaluation of TPM adoption factors in manufacturing organizations using fuzzy PIPRECIA method

PurposeThe aim of this paper states that total productive maintenance (TPM) is an improvement tool which employs the effective utilization of employees in order to enhance the reliability of the equipment in consideration.Design/methodology/approachThis paper identifies and evaluates the factors accountable for the adoption of TPM methodology in manufacturing organizations. Twenty-four factors affecting the TPM implementation are explored and categorized into five significant categories. Afterwards, these identified TPM factors have been evaluated by using a most popular Multi-criteria decision-making (MCDM) approach namely fuzzy pivot pairwise relative criteria importance assessment (F-PIPRECIA).FindingsIn this paper, through application of F-PIPRECIA, “Behavioural factor” is ranked first while “Financial factor” the last. Considering the sub-factors, “Top management support and commitment” is ranked first while “Effective use of performance indices” is ranked the last. A further sensitivity analysis indicates the factors that need higher level of attention.Practical implicationsThe result of current research work may be exploited by the top administration of manufacturing enterprises for assessing their TPM adoption status and to recognize the frail links of TPM application and improve accordingly. Moreover, significant factors of TPM can be identified and deploy them successfully in their implementation procedure.Originality/valueThe conclusion obtained from this research enables the management to clearly understand the significance of each considered factor on the adoption of TPM in the organization and hence, provides effective utilization of resources.

Increased Productivity of Packing Machines Through Implementation of Total Productive Maintenance Using the Overall Equipment Effectiveness Method Case Study of PT. GFPJ

In the world's manufacturing industry, increasing productivity is very important in fulfilling domestic and international markets as well as maintaining customer confidence. The company is trying to increase productivity in production. The fact that the packing machine is in an inefficient condition and the management is trying to implement it. in Total Productive Maintenance (TPM) to maximize the effectiveness of machine facilities in the industry. Then corrective actions are tested using the Overall Equipment Effectiveness (OEE) method, which is the calculation method used in this OEE value is determined by availability, performance and quality. The low OEE value of the packing machine at PT. GFPJ results from the availability value of = 60% for the results of the performance value of = 100% and the value of quality = 93%, it can be concluded that the OEE value obtained on the machine packing is 59.86%, while the international OEE standard is 87%, so it needs improvement. The factor that becomes a priority for improvement is the performance or performance of the machine in producing concrete, because the performance value is the lowest value of the three factors that affect the OEE value.

Assessment of critical success factors, barriers and initiatives of total productive maintenance (TPM) in selected Ethiopian manufacturing industries

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.

Implementation of Total Productive Maintenance in a Jute Bag Industry:a Case Study

In this competitive world, manufacturing industries are suffering from several problems such as breakdown of machine, production adjustments, poor working of defective equipment, poor maintenance and management, unhealthy working area and this lead to low productivity, increasing wastage, fire damage and major losses in the company’s growth. Total Productive Maintenance (TPM) approaches can be promising solution to overcome these problems. Therefore, this study attempts to evaluate the contributions TPM initiatives towards improving manufacturing performance in a Jute bag manufacturing industry in Bangladesh. Specific objectives of this study are identification and reduction of major losses by using TPM tools and evaluation of the effectiveness by analyzing Overall Equipment Efficiency (OEE). The correlations between various TPM implementation dimensions and manufacturing performance improvements have been evaluated and validated by employing overall equipment effectiveness (OEE) in the jute bag plant. In this study TPM tools such as 5S, Autonomous Maintenance, Kobetsu Kaizen, Planned Maintenance and Education and Training have been implemented in the selected company. The equipment failure losses are reduced 3.85% through continuous improvement concept. The defect rate is reduced by 1.84% by taking preventive action. Most importantly it is observed that the OEE is improved from 7.42% i.e improved the productivity as well as improved the quality of product. Journal of Engineering Science 14(1), 2023, 137-149

Integrating TPM and Industry 4.0 to Increase the Availability of Industrial Assets: A Case Study on a Conveyor Belt

As the global market becomes increasingly competitive and demanding, companies face the challenge of responding swiftly and efficiently to customer needs. To maintain a competitive advantage, organisations must optimise the usage of their assets. This study focuses on the critical role of maintenance management and presents a novel, cost-effective, and easily applicable model that integrates Industry 4.0 (I4.0) and Total Productive Maintenance (TPM) principles to enhance production processes. The proposed model incorporates a real-time monitoring system equipped with sensors, a gateway, and Internet of Things (IoT) services. These components enable data acquisition, transmission, storage, and visualisation through both mobile and fixed devices. The model’s effectiveness was validated through its implementation on a conveyor belt in a feed mill. The availability of the conveyor belt was around 89.5% before TPM implementation. After the implementation of TPM, it was possible to observe that the availability of the treadmill increased to 92.7% in a workweek of 105 h. On the other hand, it was possible to observe a considerable improvement in terms of the average time of each intervention, with a reduction of around 53%. Moreover, the model also facilitated improvements in the maintenance plan for the conveyor belt. Operators were trained to effortlessly comply with the new autonomous maintenance plan, enhancing operational efficiency. The joint application of I4.0 and TPM demonstrated significant advancements in maintenance management. The flexibility of the developed model allows for easy adaptation to monitor other condition parameters, enabling real-time decision-making for both the maintenance and production departments. This integrated approach holds the potential to drive process optimisation, ultimately contributing to improved productivity, cost-effectiveness, and competitiveness.

Implementation of Total Productive Maintenance and Lean Manufacturing in the Pharmaceutical Industry: An Empirical Study

This study aimed to determine the relationship between the implementation of total productive maintenance and lean manufacturing on overall equipment effectiveness at PT Kimia Farma Tbk Plant Banjaran. This research design is quantitative, with multiple linear regression methods to determine the independent variable on the dependent variable. Data was collected by giving questionnaires directly to respondents. This study's results show a positive and significant relationship between the Total Productive Maintenance program and the Overall Equipment Effectiveness measured at PT Kimia Farma Tbk Plant Banjaran. A positive and meaningful relationship exists between the Lean Manufacturing program and the Overall Equipment Effectiveness measured at PT Kimia Farma Tbk Plant Banjaran. TPM is one of LM's tools in terms of equipment, apart from other tools that measure process aspects such as Standard Work, 5S, VSM, JIT, Line Balancing, and SMED. A positive, simultaneous, and significant relationship exists between the combination of Total Productive Maintenance and Lean Manufacturing programs on Overall Equipment Effectiveness as measured at PT Kimia Farma Tbk Plant Banjaran. The combination of a good TPM and LM program directly causes an increase in the effectiveness and efficiency of the production process. It reduces the occurrence of production defects so that OEE also increases.

Efficiency measurement based on novel performance measures in total productive maintenance (TPM) using a fuzzy integrated COPRAS and DEA method

Total Productive Maintenance (TPM) has been widely recognized as a strategic tool and lean manufacturing practice for improving manufacturing performance and sustainability, and therefore it has been successfully implemented in many organizations. The evaluation of TPM efficiency can assist companies in improving their operations across a variety of dimensions. This paper aims to propose a comprehensive and systematic framework for the evaluation of TPM performance. The proposed total productive maintenance performance measurement system (TPM PMS) is divided into four phases (e.g., design, evaluate, implement, and review): i) the design of new performance measures, ii) the evaluation of the new performance measures, iii) the implementation of the new performance measures to evaluate TPM performance, and iv) the reviewing of the TPM PMS. In the design phase, different types of performance measures impacting TPM are defined and analyzed by decision-makers. In the evaluation phase, novel performance measures are evaluated using the Fuzzy COmplex Proportional Assessment (FCOPRAS) method. In the implementation phase, a modified fuzzy data envelopment analysis (FDEA) is used to determine efficient and inefficient TPM performance with novel performance measures. In the review phase, TPM performance is periodically monitored, and the proposed TPM PMS is reviewed for successful implementation of TPM. A real-world case study from an international manufacturing company operating in the automotive industry is presented to demonstrate the applicability of the proposed TPM PMS. The main findings from the real-world case study showed that the proposed TPM PMS allows measuring TPM performance with different indicators especially soft ones, e.g., human-related, and supports decision makers by comparing the TPM performances of production lines and so prioritizing the most important preventive/predictive decisions and actions according to production lines, especially the ineffective ones in TPM program implementation. Therefore, this system can be considered a powerful monitoring tool and reliable evidence to make the implementation process of TPM more efficient in the real-world production environment.

Implementing Total Productive Maintenance in Yemeni Company for Industry and Commerce (YCIC): Case Study

Purpose: The purpose of this research is to design fundamental base for continuous improvement in maintenance that serves improving machine’s reliability and raises the productivity, to fix strong products in the market with perfect quality and competitive price. Zero breakdowns, zero defects and zero accidents are the target to possibly improve productivity, save costs by reducing wastes and equipment longevity. Making the workplace is healthy organizational environment and better performance, increases the work team spirit by appropriate follow instruction of the implementation and mutual respect and understanding between managers and employees. Design / Methodology / Approach: The data were collected using questionnaire, company’s documentation, interview and observations for 6 months at the lines of the company. The assessment is based on the overall equipment effectiveness (OEE), productivity and profitability approach. Cause-Effect diagram and Pareto chart techniques were used for identifying the problems in the production lines. The 8 pillars and others worksheets of TPM are used for 6 months period. Finally, OEE and its indexes were used as measuring of success the TPM implementation. Findings - The suggested scheme was effective in increasing the overall equipment effectiveness from 48 % to 85 % over a 6 months period. The parameters of OEE were a direct orientation of improvements in equipment availability, performance and product quality by highly recommendation on the pillars of TPM. This work may have exploits on the consistency of TPM nature to improve maintenance scheme for a generic system. The tools and worksheets presented can be helpful to managers and operators. Originality / value: Total productive maintenance (TPM) is one of the numerous diagnostic/prognostic maintenance strategies have been employed in this study. This research has implemented an integrated OEE and its parameters/managers and normal labors in order to clarify the cause / effect to make action for the critical/chronic lines to remedy the low production. This is the first time that the TPM in this company has been placed and its impact is gained after that specific and short period.

An assessment of key performance indicators and its relationship for implementation of total productive maintenance in manufacturing sector

An assessment of key performance indicators and its relationship for implementation of total productive maintenance in manufacturing sector

Relationship between TPM practices and operational performance in soft drinks manufacturing industry

PurposeThe purpose of this paper is to investigate the relationship between total productive maintenance (TPM) practices and operational performance (OP) in soft drinks manufacturing industry, Ethiopia.Design/methodology/approachIn this study acceptability and implementation of five TPM practices (i.e., dependent factors: autonomous maintenance (AUT); safety, health and environment (SHE); education and training (EDT); focused improvement; and planned maintenance (PLM)) in soft drinks manufacturing industry have been elaborated to ascertain the benefits accrued as a result of successful TPM practices (i.e., independent variables) on OP (i.e., dependent variables). A self-administered survey seven-point Likert scale questionnaire was used for primary data collection. By using simple random sampling technique a total of 100 useable responses resulted in a 66.66 per cent response rate. Descriptive (mean, standard deviation) and inferential statistics (factor analysis, correlation, simple and multiple regression analysis) analysis were performed using Statistical Package for Social Sciences (SPSS) software (version-28) to identify the relationship and effect of TPM practices on OP. Five hypotheses were developed and tested.FindingsResults show that four of the TPM practices were positively and significantly correlated with OP. Aggregate TPM shows positive and significant correlation with OP. Four hypotheses results revealed that the AUT; SHE; EDT and PLM practices have positive and significant relationship with OP and significantly improve OP. The results also show that the TPM practices have positive and significant relationship with OP and significantly improve cost effectiveness, product quality, on-time delivery and volume flexibility.Practical implicationsThe benefits gained by TPM practices in selected soft drinks manufacturing industry have been highlighted, that could be genuine source of motivation to other companies to go in for TPM program. This research contributes to the literature by examining the contingency of various TPM enabling factors in the context of the Ethiopian soft drinks manufacturing sector, and it, therefore, provides direction to increase the success rate of TPM implementation. Study offers academics and practitioners a better understanding of the relationship and effect of the TPM practices on the OPs. Thus, practitioners will be able to make better and more effective decisions about the implementation of TPM practices for better OP results.Originality/valueThe relationship between the five factors TPM practices and OP has not yet been studied or reported in the case of soft drink manufacturing industry. The questionnaire manner and items developed, factor considered in this study, sampling method, deeply statistical data analysis techniques used, soft drink manufacturing industry, developing country like Ethiopia make this study unique and revealed the gap identification in this area. The study has contributed to the TPM literature with a better understanding of the five TPM practices and their association with a soft drink manufacturing industry OP that will provide valuable knowledge to top-management of manufacturing companies, to refine their current TPM practices and subsequently improve OP.