Total Productive Maintenance Initiatives Research Articles

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

An evaluation of transfusion of TQM-TPM implementation initiative in an Indian manufacturing industry

Purpose – The purpose of this paper is to include investigations of current status of Total Quality Management (TQM) and Total Productive Maintenance (TPM) implementation initiatives as well as benefits attained through synergetic TQM-TPM implementation in the manufacturing organization to assess roadmap followed by Indian manufacturing entrepreneur toward affecting manufacturing performance enhancements. Design/methodology/approach – The study has been carried out in the large scale manufacturing organization in the country that have implemented or are in the process of implementing TPM alone and TQM-TPM both. The study emphasizes upon comparing of business performance enhancements accrued through these quality improvement approaches. Findings – The study revealed that Transfusion of TQM-TPM initiatives can significantly contribute toward the better improvement of manufacturing performance in the organization, rather than TPM alone initiatives, also leading toward realization of core competencies for meeting global challenges. Research limitations/implications – The study is conducted to develop an understanding of contributions of TQM and TPM initiatives in Indian manufacturing industry. The present study endeavors to investigate the effect of an aggressive TQM-TPM implementation plan for strategically meeting global challenges and competition. Originality/value – The study highlights the contributions made by holistic TQM-TPM implementation in an Indian manufacturing enterprise.

Evaluating the contributions of total productive maintenance on manufacturing performance

In today's highly competitive business environment, survival and growth of manufacturers depend on their ability to offer a great variety of high quality products at an acceptable price using minimum lead time. Total productive maintenance (TPM) is an expansion of the lean enterprise culture. TPM implementation can be helpful in paving the way for these objectives. The ultimate goal of TPM is to optimise the delivery time, service level and productivity to fulfil the customer needs and expectations. The purpose of the present study is to evaluate the contributions of total productive maintenance (TPM) initiatives towards improving manufacturing performance in an Indian manufacturing industry. The study revealed that proactive TPM initiatives have helped the manufacturing organisation immensely in improving synergy between the maintenance department and rest of the manufacturing functions, resulting in elimination of defects, improved manufacturing process reliability and OEE, affecting cost reductions thereby strengthening sustainability efforts of the organisations to meet cut-throat global competition for business excellence.

Effectiveness of TPM implementation with and without integration with TQM in Indian manufacturing industries

Purpose – The purpose of this paper is to evaluate and extract various significant factors influencing the implementation of total quality management (TQM) and total productive maintenance (TPM) on business performance for the following approaches: TPM alone; both TQM-TPM combined for improving manufacturing performance in the Indian manufacturing industry. Design/methodology/approach – In the present study, 94 manufacturing organizations have been extensively surveyed, to ascertain the contributions made by TQM and TPM initiatives in the Indian manufacturing industries toward realizing manufacturing performance improvements. The correlations between various TQM and TPM implementation issues and manufacturing performance improvements have been evaluated and validated by employing various statistical tools. Findings – This paper illustrates how the synergistic relationship of TQM and TPM paradigms can be helpful for Indian manufacturing industries to enhance overall business performance. The major objectives of this research is to examine, the effectiveness of performance parameters (dependent variables) and factors of implementation (independent variables) of companies implementing TPM alone and TQM-TPM combined approach to improve their business performance and how the support of TQM provides a synergetic effect on TPM's contribution in improving better business performance. Originality/value – TQM and TPM, are such popular initiatives employed by the manufacturing organizations as performance improvement techniques. These programs are employed world over for attaining customer satisfaction, reliability, productivity, market share, profitability and even survival. The study stresses upon the need for improving coordination between manufacturing parameters and other organizational quality improvement initiatives through transfusion of TQM and TPM and to examine the impact of experience in terms of time period on effectiveness of performance parameters when TQM is supported by TPM for Indian manufacturing companies.

Total productive maintenance: a tool for envisaging manufacturing competence

The manufacturing organisations, in the recent last few decades have been driven by drastic competitive forces, to imbibe the state-of-art organisational, operational and strategic practices. The global marketplace has been pushing manufacturing managers to reconsider the impact and importance of increasing equipment availability and utilisation, increasing maintenance productivity, resource utilisation and increasing quality and responsiveness of maintenance services in achieving world class status. Total Productive Maintenance (TPM) has been envisaged as a potent plant management tool for achieving the organisational objectives of achieving core competence in the dynamic environment. TPM with its multifaceted initiatives like resource management, corrective, preventive and predictive initiatives, performance measurement and improvement initiatives has been significant to manufacturing organisations. The study highlights the contributions of strategic TPM initiatives on manufacturing performance and demonstrates the true potential of TPM in achieving manufacturing competence.

Analysis of barriers of total productive maintenance (TPM)

In the highly competitive environment, to be successful and to achieve world-class-manufacturing, organizations must possess both efficient maintenance and effective manufacturing strategies. A strategic approach to improve the performance of maintenance activities is to effectively adapt and implement strategic TPM initiatives in the manufacturing organizations. Total productive maintenance (TPM) is not easy to adopt and implement, due to presence of many barriers. The purpose of this paper is to identify and analyse these barriers. A questionnaire based survey was conducted to rank these barriers. The results of this survey and interpretive structural modelling approach have been used to model and analyse key barriers and drive managerial insights.

A case study of total productive maintenance implementation at precision tube mills

PurposeThe purpose of this paper is to investigate the contributions of successful total productive maintenance (TPM) initiatives to competitive manufacturing. It also seeks to critically examine the implications of strategic TPM implementation initiatives in an Indian manufacturing organisation.Design/methodology/approachThe study is carried out at a precision tube mill that has successfully implemented TPM and has reaped significant benefits as a result of TPM implementation, to study the TPM implementation issues and achievements realised as a result of strategic TPM implementation. The approach is directed towards the justification of TPM implementation for its support to competitive manufacturing in Indian industries.FindingsThe study reveals the exploits of Indian entrepreneurs with TPM practices and highlights the contributions of TPM in realising the overall organisational goals and objectives. The study reveals that strategic TPM initiatives can significantly contribute towards the improvement of manufacturing performance in the organisation, leading to the realisation of core competencies for meeting global challenges.Research limitations/implicationsThe study is conducted to develop an understanding of contributions of TPM initiatives towards building manufacturing competencies in Indian manufacturing industry. The present study endeavours to investigate the effect of an aggressive TPM implementation plan for strategically meeting global challenges and competition.Practical implicationsThe study highlights the contributions of strategic TPM initiatives to organisational performance and highlights the need for the successful management of TPM programmes for establishing sustained maintenance improvement initiatives.Originality/valueThe study highlights the contributions made by holistic TPM implementation at a precision tube mills in an Indian manufacturing enterprise.

Investigation of manufacturing performance achievements through strategic total productive maintenance initiatives

In the contemporary highly challenging environment, a reliable production system has been considered as a crucial factor for competitiveness. Thus, achieving excellence in maintenance issues has to be treated as a strategic issue for manufacturing organisations to create world-class-manufacturers. The ever increasing demands on the manufacturing organisations have contributed to the complete overhaul of maintenance practices in manufacturing enterprises. Total productive maintenance (TPM) has been accepted as the most promising strategy for improving maintenance performance in order to succeed in a highly demanding market arena. The objective of the study is to investigate the manufacturing performance achievements through strategic TPM initiatives in Indian manufacturing industry. The empirical evidence has been presented to support relationships between critical TPM pillar initiatives and strategic manufacturing performance achievement parameters. These inter-relationships can be used to understand the effect of various TPM success factors towards the realisation of an organisation's objectives of growth and sustainability.

Justification of total productive maintenance initiatives in Indian manufacturing industry for achieving core competitiveness

PurposeThe purpose of this paper is to develop an understanding of contributions of total productive maintenance (TPM) initiatives towards building core competencies in Indian manufacturing industry. This paper critically examines the implications of TPM implementation initiatives in Indian manufacturing organizations.Design/methodology/approachIn this study a large number of manufacturing organizations have been extensively surveyed to ascertain contributions made by TPM initiatives in the Indian manufacturing industries towards realizing core competencies. The study involves working out the correlations between various TPM implementation dimensions and core competencies, and employs various statistical tools for extracting significant factors contributing effectively towards realization of core competencies.FindingsThe study reveals that organizational leadership and involvement, traditional maintenance practices, successful adaptation of effective TPM initiatives can significantly contribute towards accruing core competencies in the organization. The study highlights that the holistic TPM initiatives outscore the traditional maintenance practices towards improving the manufacturing performance (MP). The study establishes that focused TPM implementation over a reasonable time period can significantly contribute towards realization of core competencies in MP.Research limitations/implicationsThe study has been conducted to ascertain the contributions of TPM initiatives for achieving core competencies in manufacturing organizations. However, sector‐wise studies can also be conducted to evaluate the contributions of TPM implementation towards performance enhancement under the specific situations.Practical implicationsThe present study identifies the impact of key TPM initiatives dimensions on organizational performance and highlights the need for aligning organizational efforts in establishing maintenance improvement initiatives for realizing improvements in performance of manufacturing organizations.Originality/valueThe paper investigates the status of TPM initiatives in the Indian context and the preparedness of Indian manufacturing industry to meet the challenges posed by the western world by employing proactive TPM strategies.

Strategies and success factors for overcoming challenges in TPM implementation in Indian manufacturing industry

PurposeThe purpose of this study is to evaluate the challenges before Indian manufacturing organizations for adapting to proactive total productive maintenance (TPM) initiatives. The aim of this research is to critically examine the factors influencing the implementation of TPM practices in the Indian manufacturing industry, and to devise an overall maintenance strategy for overcoming obstacles to successful TPM implementation.Design/methodology/approachThe study focuses on systematic identification of obstacles in TPM implementation and working out success factors towards improving manufacturing performance in Indian industry through strategic TPM initiatives.FindingsThe study highlights the strong potential of TPM implementation initiatives in affecting organizational performance improvements. The paper reveals that implementing TPM is by no means an easy task, which is heavily burdened by organizational, cultural, behavioral, technological, operational, financial, and departmental barriers.Research limitations/implicationsThe study has been conducted in Indian manufacturing organizations to formulate the critical success factors and enablers for overcoming obstacles to successful TPM implementation with regard to its preparedness to face global challenges.Practical implicationsThe study stresses the need for improving the synergy between the maintenance function and other organizational quality improvement initiatives in the organizations, to establish maintenance as a competitive strategy for meeting the challenges of a highly competitive environment.Originality/valueThe study highlights the difficulties faced by Indian manufacturing organizations in their attempt to implement TPM initiatives in order to improve organizational efficiency.

An evaluation of TPM initiatives in Indian industry for enhanced manufacturing performance

PurposeThe purpose of this paper is to evaluate the contributions of total productive maintenance (TPM) initiatives towards improving manufacturing performance in Indian Manufacturing Industry.Design/methodology/approachIn this study, a large number of manufacturing organizations have been extensively surveyed, to ascertain contributions made by TPM initiatives in the Indian manufacturing industries towards realizing manufacturing performance improvements. The correlations between various TPM implementation dimensions and manufacturing performance improvements have been evaluated and validated by employing various statistical tools.FindingsThe research focuses upon the significant contributions of TPM implementation success factors like top management leadership and involvement, traditional maintenance practices and holistic TPM implementation initiatives, towards affecting improvements in manufacturing performance in the Indian industry. The inter‐relationships between various TPM implementation success factors with the manufacturing performance improvement parameters have been evaluated, to efficiently manage the TPM implementation program to realize organizational objectives of growth and sustainability.Research limitations/implicationsThe study establishes that focused TPM implementation over a reasonable time period can strategically contribute towards realization of significant manufacturing performance enhancements.Practical implicationsThe study stresses upon the need for improving the synergy between maintenance function and other organizational quality improvement initiatives in the organizations, to establish maintenance as a competitive strategy for meeting the challenges of highly competitive environments.Originality/valueThe study highlights the strong potential of TPM implementation initiatives in affecting organizational performance improvements. The achievements of Indian manufacturing organizations through proactive TPM initiatives have been evaluated and critical TPM success factors identified for enhancing the effectiveness of TPM implementation programs in the Indian context.

An evaluation of TPM implementation initiatives in an Indian manufacturing enterprise

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.

Implementing TPM in plant maintenance: some organisational barriers

Since the 1980s, quality initiatives, seen as critical for greater competitiveness, have gained much attention from British management under the influence of Japanese management principles. This has resulted in a widespread adoption of quality techniques such as quality circles, teamworking, customer care, total quality management (TQM) and total productive maintenance (TPM), etc. This paper reports the finding of a study of the production and maintenance function of four processing/manufacturing companies. It intends to highlight the difficulties that these companies have been faced with in their attempt to implement TPM initiatives between the production and maintenance departments in order to improve organisational efficiency. The paper concludes that implementing TPM is by no means an easy task, which is heavily burdened by political, financial, departmental and inter‐occupational barriers.