Total Productive Maintenance Pillars Research Articles

Operational excellence in total productive maintenance: statistical reliability as support for planned maintenance pillar

PurposeTotal productive maintenance consists of strategies and procedures that aim to guarantee the entire functioning of machines in a production process so that production is not interrupted and no loss of quality in the final product occurs. Planned maintenance is one of the eight pillars of total productive maintenance, a set of tools considered essential to ensure equipment reliability and availability, reduce unplanned stoppage and increase productivity. This study aims to analyze the influence of statistical reliability on the performance of such a pillar.Design/methodology/approachIn this study, we utilized a multi-method approach to rigorously examine the impact of statistical reliability on the planned maintenance pillar within total productive maintenance. Our methodology combined a detailed statistical analysis of maintenance data with advanced reliability modeling, specifically employing Weibull distribution to analyze failure patterns. Additionally, we integrated qualitative insights gathered through semi-structured interviews with the maintenance team, enhancing the depth of our analysis. The case study, conducted in a fertilizer granulation plant, focused on a critical failure in the granulator pillow block bearing, providing a comprehensive perspective on the practical application of statistical reliability within total productive maintenance; and not presupposing statistical reliability is the solution over more effective methods for the case.FindingsOur findings reveal that the integration of statistical reliability within the planned maintenance pillar significantly enhances predictive maintenance capabilities, leading to more accurate forecasts of equipment failure modes. The Weibull analysis of the granulator pillow block bearing indicated a mean time between failures of 191.3 days, providing support for optimizing maintenance schedules. Moreover, the qualitative insights from the maintenance team highlighted the operational benefits of our approach, such as improved resource allocation and the need for specialized training. These results demonstrate the practical impact of statistical reliability in preventing unplanned downtimes and informing strategic decisions in maintenance planning, thereby emphasizing the importance of your work in the field.Originality/valueIn terms of the originality and practicality of this study, we emphasize the significant findings that underscore the positive influence of using statistical reliability in conjunction with the planned maintenance pillar. This approach can be instrumental in designing and enhancing component preventive maintenance plans. Furthermore, it can effectively manage equipment failure modes and monitor their useful life, providing valuable insights for professionals in total productive maintenance.

Authorship Correction: Application of the Total Productive Maintenance to Increase the Overall Value of Equipment Effectiveness on Ventilator

Correction of: https://josi.ft.unand.ac.id/index.php/josi/article/view/642 . DOI: 10.25077/josi.v22.n1.p52-60.2023 A ventilator machine is a medical device that plays an important role in handling Covid-19 cases during a pandemic. Covid 19 patients are arriving at a referral hospital in Jakarta, meaning that the hospital must prepare its medical equipment, including a ventilator machine. The ventilator machine experienced problems because the efficiency of the machine decreased so many patients waited in the ICU room. Machine effectiveness has an average value of 62.26% so it has an impact on disrupting patient services at home. The purpose of this research is to look for factors that cause the lack of effective value of ventilator machines and find effective solutions to increase the effectiveness of ventilator machines so that they can serve Covid-19 patients during a pandemic. This research method combines Focus Group Discussion in determining 5W+1H and implementing the pillars of Total Productive Maintenance to improve the Overall Effectiveness of Equipment on Ventilator machines. This study found a breakdown factor of 54.10%, idle and minor loss of 41.20%, and others of 4.70%. The effect of overall improvement has been able to increase the average effectiveness value by 85.00% from Sep 2021-Feb 2022, so this is supported by the hospital's program in terms of increasing the effectiveness of machines in patient care.

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.

Application of the Total Productive Maintenance to Increase the Overall Value of Equipment Effectiveness on Ventilator Machines

A ventilator machine is a medical device that plays an important role in handling Covid-19 cases during a pandemic. Covid 19 patients are arriving at a referral hospital in Jakarta, meaning that the hospital must prepare its medical equipment, including a ventilator machine. The ventilator machine experienced problems because the efficiency of the machine decreased so many patients waited in the ICU room. Machine effectiveness has an average value of 62.26% so it has an impact on disrupting patient services at home. The purpose of this research is to look for factors that cause the lack of effective value of ventilator machines and find effective solutions to increase the effectiveness of ventilator machines so that they can serve Covid-19 patients during a pandemic. This research method combines Focus Group Discussion in determining 5W+1H and implementing the pillars of Total Productive Maintenance to improve the Overall Effectiveness of Equipment on Ventilator machines. This study found a breakdown factor of 54.10%, idle and minor loss of 41.20%, and others of 4.70%. The effect of overall improvement has been able to increase the average effectiveness value by 85.00% from Sep 2021-Feb 2022, so this is supported by the hospital's program in terms of increasing the effectiveness of machines in patient care.

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.

Designing Lean Maintenance Using Total Productive Maintenance Method – A Case Study at Wiring Harness Production

Consumer demand for 4-wheeled and 2-wheeled motorized vehicles in Indonesia is increasing yearly. In 2022, car sales increased by 18.1%. At the same time, motorcycle sales increased by 3.24%. Automotive companies will compete with each other to meet the needs of consumers in the future. This is also true for automotive parts suppliers. PT XYZ is a company that supplies wiring harnesses for the needs of motorized vehicle components. Currently, the company is facing a problem with overtime of up to 4 hours in several production lines. The company missed the production target because the production plan had not considered any waste that happened on the production floor. Downtime of machines can stop production on the line. Downtime can occur due to machine failure. The company must choose the proper steps for resolution. If waste continues to be ignored, the company will struggle to compete with its competitors. This research aims to solve the waste problem through the Total Productive Maintenance (TPM) Method. Several steps are used to solve the problem: root cause analysis, determining the TPM pillars applied, RCM, and realization of TPM pillars. The research results are lean maintenance design from completing TPM pillars, such as autonomous maintenance, planned maintenance, and development management.

Axiomatic design for lean autonomous maintenance system: an application from textile industry

PurposeAutonomous maintenance (AM), one of the pillars of total productive maintenance (TPM), aims to achieve performance toward zero defects and zero breakdowns. AM system equipped with comprehensive lean tools provides continuous improvement during the AM activities. Despite its long duration, establishing a lean AM system with a robust guideline would provide significant benefits such as high quality and short lead time. Therefore, AM design approach should be provided in a holistic and detailed manner. This study aims to develop a framework for AM design, including preliminary, reactive, preventive and proactive steps using the axiomatic design (AD).Design/methodology/approachRequirements and technical parameters of the AM system are explored with AD. An extensive literature review and a real-life application are presented.FindingsThe proposed design was validated by adapting the proposed roadmap to a textile manufacturing system in Turkey. The application results justify the established AM system design with an average downtime improvement of 69.2% and the average elapsed time between two failures improvement of 65.1% for apparel department.Originality/valueThis study has the novelty of establishing an overall AM system design with all of its stages stepwise. It presents a comprehensive guideline in terms of integration of lean philosophy into AM design by generating maintenance-related use cases for lean tools. The developed approach facilitates creating and analyzing complex systems to improve maintenance implementations while reducing nonvalue-added operations.

ANALISIS PENERAPAN TOTAL PRODUCTIVE MAINTANANCE (TPM) DENGAN MENGGUNAKAN METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE) DI PT XYZ

This study aims to analyze the application of Total Productive Maintenance (TPM) in a pharmaceutical company in Bandung which is currently moving from an increasingly widespread industrial location, so that there are new products. TPM is a useful system in increasing productivity, increasing productivity on various production tools and equipment with only the necessary maintenance investment. Evaluation of the implementation of the TPM pillars is carried out through the overall equipment effectiveness (OEE) analysis method, visual management, lost time injury (LTI) and time accident rate (TAR). Another result is that the implementation of the planned maintenance pillar has not reached the target according to the standard, both in terms of availability and performance rate parameters. The pillar that has not been implemented in this company is autonomous maintenance. The conclusion from this research is that PT XYZ has not effectively implemented TPM in its factory operations. The recommendation from this research is the need for the implementation of autonomous maintenance pillars and scheduled replacement of engine components to solve problems that exist in the factory and can be focused in particular on critical work areas

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.

The Relationships between the Pillars of TPM and TQM and Manufacturing Performance Using Structural Equation Modeling

This paper examines the direct and indirect relationships between the pillars of total quality management (TQM) and total productive maintenance (TPM) and investigates their effects on manufacturing performance (MPR) using structural equation modeling. Three structural models were developed with their corresponding hypotheses. Data were then collected from thirty industrial firms in Jordan. A descriptive statistical analysis was followed by an analysis of variance (ANOVA). The structural models were analyzed to draw conclusions about the model hypotheses and identify the most influential TPM and TQM pillars on MPR. Significant variations were noticed among firms in the implementation levels of the TPM, TQM, and MPR pillars. Further, it was found that TPM directly and indirectly influences MPR. Furthermore, TPM pillars have a larger impact on MPR than TQM. Research hypotheses are suggested to be tested individually on small-, middle-, and large-sized firms. This research provides valuable information on top management in the industrial sector, on the significant relationships between the pillars of TPM, TQM, and MPR and supports them in identifying important TQM/TPM pillars which they should focus on in order to enhance MPR.

Analisis peningkatan kinerja pemeliharaan mesin dengan Total Productive Maintenance (TPM) pada mesin boiler pabrik kelapa sawit PT.Multi Karya Persada Indonesia Di Kabupaten kapuas Kalimantan Tengah

The implementation of Total Productive Maintenance (TPM) is to improve maintenance performance in the production machine at PT. Multi Karya Persada Indonesia In Kapuas Regency, Central Kalimantan This is descriptive research. The analysis used overall equipment effectiveness (OEE), OEE six big losses, Pareto diagrams, and cause and effect diagrams. As a result of PTPN VI PT. Multi Karya Persada Indonesia In Kapuas Regency, Central Kalimantan had a problem with machine performance value, it was lower than the world-class standard of about 71.85% (≤ 95%). Caused of the low OEE value (65,16%) is high idling and minor stoppages and reduced speed losses value. To improve this problem the company is implementing TPM, with planning 8 TPM pillars as the foundation for implementing TPM.

An Autonomous Maintenance Design Based on Overall Resource Effectiveness (ORE) Analysis: A Case Study of Paving Molding Machine

The paving molding machine is one of the machines used to produce black paving at PT XYZ. Based on the historical data from the engineering maintenance department, this machine has the highest breakdown frequency which affected the low performance and productivity of the machine. To solve this problem, the effectiveness of the paving molding machine was analyzed using overall resource effectiveness (ORE) methods. ORE aims to analyze machine indicators, consisting of readiness, availability of the facility, changeover efficiency, availability of material, availability of manpower, performance efficiency, and quality rate. The ORE analyzed result shows that values of performance efficiency of paving molding machine were 64.54% and still below the standards of the ORE. To increase the ORE, a design of autonomous maintenance (AM) was proposed. The proposed design means the operator is given the responsibility to maintain the basic condition of the machine to minimize the damage of the paving molding machine at PT XYZ. The result of ORE analysis, especially in the performance efficiency, will be an input for the engineering maintenance department to make an AM basic design that can be executed by each of the machine's operators. In general, this research’s novelty is to combine the application of the ORE method with the AM basic design, whereas the AM is one of the pillars of total productive maintenance (TPM).

Implementation of Autonomous Maintenance in Total Productive Maintenance

The purpose of this research is to increase the Avaibility rate, Performance rate and OEE value on pipe extruder line 9 at PT. Wahana Tunas Utama Rucika which is engaged in manufacturing PVC pipe products (Poly Vinyl Clhoride). In order to increase productivity, Total Productive Maintenance (TPM) is measured by calculating OEE. The method used in solving this problem the 8 pillars of TPM with the Autonomous Maintenance (AM) method. The implementation of the TPM pillar aims to increase the knowledge, responsibility and skills of production operators related to machines, so that overall productivity will increase. AM uses a structured and documented system so that this program can run consistently. The results of the implementation of the proposed improvements showed that the Availability rate had to increase by 3.61%, the Performance rate had to increase by 3.41% and OEE had to increase by 3.25% after the proposed improvements 6 months.

Evaluation of total productive maintenance implementation in manufacture

This paper describes an evaluation of the Total Productive Maintenance (TPM) implementation. The evaluation is done by comparing the results of the application using the 5S foundation and the eight pillars of TPM with the company’s achievement goal of 80%. 5S foundation includes Sort, Set in Order, Shine, Standardize, and Sustain. TPM method consist of eight pillars are include Autonomous Maintenance, Focussed Maintenance, Planned Maintenance, Quality Management, Education and Training, Safety, TPM offices, and Development Management. The evaluation of the TPM implementation is carried out using the nominal group technique method. The group consists of 10 managers, and supervisors are directly involved in implementing 5S on the production floor. The assessment results obtained on the 5S foundation application of 82%, Autonomous Maintenance of 83%, Focussed Maintenance of 75%, Planned Maintenance of 80%, Quality Management of 84%, Education and Training of 88%, Safety, Health & Environment of 78%, TPM office of 73%, and Development Management of 75%.

Maintenance Maturity Level Identification using MABAC Method: An Adaptation of TPM Pillars in a Public Service Sector

Having systematic maintenance practices does sustain the lifecycle of the facilities. Hence, engineers have always been seeking for practical approaches toward providing better maintenance scheme. Such attempts have resulted in the appearance of numerous maintenance management models including the most commonly accepted one, that is, the total productive maintenance (TPM). Although the concept of TPM and its corresponding pillars have extensively been investigated in the recent literature of Maintenance Engineering and Management, the majority of the previous research attempts, including the multi-criteria decision making (MCDM) applications, have handled them within the context of the manufacturing sector; and almost none of them have been applied in the services sector. This paper proposes the multi-attributive border approximation area comparison (MABAC) method, a newly developed MCDM technique, as a tool upon which eight TPM pillars are evaluated in order to identify the maintenance maturity level in a public service sector. The investigations indicate that the proposed model equips maintenance engineers with an insight into the mechanism upon which TPM pillars can operate effectively. The results of the proposed model indicate that the investigated institution is generally not matured enough to be up to the desired level of TPM performance.

TPM Maintenance Management Model Focused on Reliability that Enables the Increase of the Availability of Heavy Equipment in the Construction Sector

The purpose of this paper is to present a maintenance study focused on total productive maintenance (TPM) and reliability-centered maintenance (RCM). Its approach is based on the first pillars of TPM, preventive and autonomous maintenance, as well as the FMEA analysis of RCM for maintenance analysis, which was conducted in this study. The implementation of TPM was successful in that various preventive maintenance (PM) policies assigned to the assets were implemented and it was demonstrated that TPM application in the construction industry could reduce the excessive accumulation of maintenance with the same effective optimization, and with support from RCM analysis and its heavy equipment systems analysis. Excessive corrective maintenance accounts for high investment and delay rates in work times of the assigned project. Traditional methods of availability guarantee, such as reactive or routine maintenance, are insufficient to satisfy a heavy equipment maintenance plan; therefore, what is called for is the systematic application of RCM and TMP because they allow the selection and application of effective PM tasks. An approach that develops and thoroughly analyzes the strategies of continuous corrective and PM is used with an atmosphere of uncertainty and with operational data limited by criticism. Results show a 90% improvement in availability.

The Measurement and Improvement of Effectiveness in K-440 Haul Truck Using Overall Equipment Effectiveness in Coal Mining Company

The objectives of this study were to determine the effectiveness of K-440 haul trucks based on Overall Equipment Effectiveness (OEE) calculation, to find out the main factors that caused the ineffectiveness of K-440 haul trucks based on fishbone diagram and Failure Mode and Effect Analysis (FMEA), and to analyze the proposed implementation of appropriate improvements to overcome the main problems of K-440 haul trucks. The method used was the mixed method, and the type of research was descriptive. The analysis methods used were OEE, fishbone diagram, and FMEA. The results show that the average effectiveness of the three K-440haul trucks is still far below international standards, which is 44,99%. The material is a significant factor that causes low OEE based on fishbone diagram analysis. There are five problems based on the Risk Priority Number (RPN) critical value from FMEA analysis, namely transmission which is not functioning properly, worn brake lining, unrotated propeller shaft on the shaft, cracked brake drum, and broken spring. Then, the implementation of eight pillars of Total Productive Maintenance (TPM) is proposed in overcoming the main problem of K-440haul trucks. Based on these results, the company needs to implement eight pillars of TPM and carry out OEE calculations regularly.

Analisis peningkatan kinerja pemeliharaan mesin dengan Total Productive Maintenance (TPM) pada mesin boiler pabrik kelapa sawit PT. Perkebunan Nusantara VI unit usaha Rimbo Dua Tebo-Jambi

The implementation of Total productive Maintenance (TPM) is to improve maintenance performance in production machine at PT. Perkebunan Nusantara VI Rimbo Dua. This is a descriptive research. The analysis used overall equipment effectiveness (OEE), OEE six big losses, pareto diagrams and cause and effect diagrams. As a result PTPN VI Rimbo Dua had a problem about machine performance value, it was lower than the world class standard about 71.85% (≤ 95%). Caused of the low OEE value (65,16%) is high idling and minor stoppages and reduced speed losses value. To improve this problem the company is implementing TPM, with planning 8 TPM pillars as the foundation for implementing TPM.Keywords: Total Productive Maintenance, Pareto Diagram, Cause and Effect Diagram

Base Principles and Practices for Implementation of Total Productive Maintenance in Automotive Industry

Purpose: IATF 16949:2016 standard requirements do not represent a totally new approach of quality improvement within the automotive industry. The change of the last, from 2009 year ISO/TS), the quality management standard is only an expected consequence of changes, which, in managerial systems, was brought by ISO Organization in 2012 (Annex SL). Implementation of the Total Productive Maintenance (TPM) requires several important steps. The article describes framework of TPM implementation on a basis of PDCA (P-plan; D-do; C-check; A-Act) cycle and evaluates influence of Occupational health and safety pillar (OHS) on the “stability” of TPM house.Methodology/Approach: Individual steps of TPM implementation are analysed and added with suitable tools for making the effective integration of TPM and IATF (which is expansion of ISO 9001:2015).Findings: Implementation of autonomous maintenance and other TPM pillars requires support from management. Although the 5S tool is understood as a basic TPM tool, knowledge from its implementation suggest the fact that 5S is also a significant tool of management integration within organisation.Research Limitation/Implication: Research presented in this article is influenced of the maturity of organisation as well as its size and types of its activities.Originality/Value of paper: Method of TPM implementation analysis in the conditions of integrated approach with an emphasis on 5S and its relation to OHS management is original approach.

Maintenance optimisation through quality management: a case study in 'Alzinc' Plant in Algeria

The aim of this paper is to apply the maintenance optimisation through quality management for a real-life industrial plant in Algeria, 'Alzinc' that have obtained various certifications (ISO 9001, ISO 14001) and is moving towards a new integrated management. The purpose consists of maintaining production activities without reducing the equipment efficiency as well as the quality of the products, the workers safety and the environment protection. In our study, maintenance optimisation combines two innovative and strategic methods, taking into account the social and cultural local background. In this case, it becomes crucial to identify indigenous culture specificities that could be integrated to universal strategic methods and techniques. Thus, our methodology relies upon the combination between reliability centred maintenance (RCM) and total productive maintenance (TPM), using the four first pillars with the aim of achieving a maximal efficiency of the production system (axis no. 1). Results show that our approach could be generalised to all the plant workshops, et allows the implementation of the other TPM pillars, in order to improve and secure the plant optimal production (axis no. 2).