Total Productive Maintenance Implementation Research Articles

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.

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.

Factors Influencing Total Productive Maintenance Implementation for Thermal Generation Plants

This study accepts that the technical and administrative factors can amplify effective total productive maintenance (TPM) implementation at thermal generation plants. It is noted that there is a limited number of studies that have attempted to understand the subject of TPM implementation in the energy sector. Noting this shortcoming, the authors thought it crucial to generate empirical evidence on the factors influencing effective TPM implementation for thermal generation plants, with evidence from gas-fired plants. A sample of 88 respondents was selected and consulted. Data were collected through questionnaires and analyzed quantitatively by inferential statistics and qualitatively through thematic analysis using SPSS version 20.0. Confirmatory factor analysis (CFA) was performed through LISREL software version 8.0. On inferential analysis, correlation, regression and ANOVA were performed. Multiple regression analysis results indicate that administrative factors, including management support, TPM awareness, employee participation and strategic planning, positively and significantly influence TPM implementation. Also, technical factors comprising planned maintenance, autonomous maintenance, quality maintenance and early equipment management positively influence TPM implementation at thermal generation plants. The correlation coefficient for all factors was at least 0.6, and the p-value was less than 0.05, suggesting that the study’s independent variables reliably predict the dependent variable. The additional factors influencing TPM implementation include training and education, organization of the workplace, root cause analysis and continuous improvement. From this juncture, the study concludes that effective TPM implementation in the energy sector, especially at thermal generation plants, can be accomplished if many administrative and technical factors are considered. These factors comprise management support, TPM awareness, strategic planning, employee participation, workplace organization, training and education, planned maintenance, autonomous maintenance, quality maintenance, early equipment management, continuous improvement and root cause analysis.

Total Productive Maintenance (TPM) Implementation to ImproveMachine Efficiency

The company focuses on producing quality products by implementing the Toyota Production System, known as TPS. The current constraint is the absence of maintenance on the Leak Test, thereby reducing production profits caused by high engine damage. This also causes the average repair time for the Leak Test Model 4L45W engine to be above the repair target set by the company, where the company targets an average repair time per month of 12 minutes. For this reason, corrective steps are needed so that the production process runs smoothly according to operational standards. This step involves proposing the implementation of Total Productive Maintenance (TPM). It is known that the average Overall Equipment Effectiveness (OEE) Leak Test machine in June–August was 60.09%. The Japan Institute of Plant Maintenance (JIPM) stipulates that if the OEE value is equal to 60%, it indicates that there is a lot of room for improvement. After implementing Total Productive Maintenance (TPM) on the Leak Testin September, the OEE value rose to 94.33%, and the average monthly repair timemet the company's target of 9.2 minutes. This greatly affects the cost of production due to lower production costs due to overtime. This indicates improvement, and the first step in the proposed implementation of the Total Productive Maintenance Machine Leak Test model 4L45W is said to be successful

Implementation of Total Productive Maintenance in a Local Pharmaceutical Manufacturing Company in the Philippines

This paper determines the implementation of total productive maintenance (TPM) at a pharmaceutical manufacturing company in the Philippines. It also assesses the significance of TPM practices from the viewpoint of employees involved in production. A total of 44 employees participated in the survey. The data gathered were analyzed using Microsoft Excel 2019 Data analysis. The extent of TPM implementation was ranked by the value of the weighted mean, the practices that had the higher weighted average, implemented to a great extent. The significance of TPM practices was tested with the aid of a t-test statistical tool at a hypothesized mean of 2.5. The findings revealed that the manufacturing company implemented TPM practices to a high extent to maintain integrity and improve production quality by reducing downtime through preventive maintenance, technology assessment and usage, and employee involvement in maintaining their equipment. The results also indicated the significance of TPM practices in improving a company’s production quality. The results of the study provide guidance and references to improve maintenance procedures and improve productivity.

Implementation of Total Productive Maintenance in Industry

Implementation of Total Productive Maintenance in Industry

Promoting employee participation in operation and maintenance of green office building by adopting the total productive maintenance (TPM) concept

Green building gains its popularity by having various benefits like optimising energy consumption, promoting long-term cost savings, and addressing global climate change. Inevitably, inappropriate operation and maintenance practice becomes a barrier in sustaining green buildings. Thus, there is an urgent need to recommend a sound operation and maintenance strategy that can tackle the issues. Total Productive Maintenance (TPM) is seen as the comprehensive strategy, provided the organisation employees can take part in the operation and maintenance activities. So, this paper aims to investigate the TPM enablers to encourage the employee participation in operation and maintenance activities of green buildings. Seven TPM enablers were identified via literature review. Then, 417 responded questionnaires were analysed to examine the association between the TPM enablers and employee participation. Subsequently, semi-structured interviews were carried out to verify and further elaborate the survey results. The findings demonstrated that all determined TPM enablers have significant associations with employee participation. The regression analysis further filtered and retained only three TPM enablers as the significant predictors of employee participation. This study is valuable to the organisations in effort to implement TPM in operation and maintenance of green buildings. It signifies the importance of knowledge, awareness, and communication to promote employee participation in operation and maintenance. It also aids to plan and conduct the training and education programmes in a more rational direction prior to the TPM implementation.

Proposal for a maintenance management system based on the lean philosophy and industry 4.0

Purpose: Develop a new model that combines the concepts of Maintenance, Lean Philosophy, and Industry 4.0 to improve maintenance management. Methodology/Approach: For the elaboration the following methodology was used: Bibliographic review of the existing models of joint application: Maintenance, Lean Philosophy, and Industry 4.0. Critical analysis of the existing models of joint application of the three concepts. Preparation of the model proposal and analysis of the results. Findings: The model developed is easy to apply, flexible and inexpensive, being a useful tool for both the maintenance and production areas, in any size and industrial area. Research Limitation/implication: One of the limitations is the distance between the devices that make up the system, as it can influence their performance. The implementation of Total Productive Maintenance can present some challenges within companies. Originality/Value of paper: The study presents a new model to improve maintenance management, being unique since the existing models are mostly focused on predictive maintenance. The system also allows the introduction of the monitoring of other important parameters such as vibrations, temperature among others.

Total productive maintenance (TPM); as a vital function in manufacturing systems

Maintenance is a vital function in manufacturing systems for maintaining quality. During the coming period two ideas are evolved Total Productive Maintenance and Total Quality Management simultaneously with other facts to attain excellence in production systems. Various feature of putting into practice Total Productive Maintenance (TPM) is expressed and examined in this study. Total productive maintenance is explained thoroughly, the philosophy, planning, improvements, goal setting and developments of implementation plans. The eight pillars of TPM are explained. Various aspect of implementation of TPM is elaborated. Also the benefits of TPM are explained.