TPM Implementation Research Articles

Development and validation of TPM implementation practices in industries: investigation from indian SMEs

Development and validation of TPM implementation practices in industries: investigation from indian SMEs

Measuring the effects of TQM and TPM implementation on the performance of the construction industry

Measuring the effects of TQM and TPM implementation on the performance of the construction industry

Measuring the effects of TQM and TPM implementation on the performance of the construction industry

Measuring the effects of TQM and TPM implementation on the performance of the construction industry

Total productive maintenance and companies performance: a case study of fast moving consumer goods companies

TPM implementation by FMCG firms in Ado/Ota industrial hub of Ogun State Nigeria was investigated, and its influence on the firm's performance was analyzed. Primary data were collected through the administration of an online questionnaire. A total number of 98 respondents participated in this research. The analysis was conducted through descriptive analysis and structural equation model (SEM) using a smart partial least square (PLS) software. It was observed that TPM implementation had a positive influence on firms' performance. The descriptive analysis. It noted that most firms explored in this study had implemented TPM. It implies that above ninety percent of companies in the industrial hub are practicing TPM. The data employed in this research are limited to those obtained from FMCG firms in Ado/Ota in Ogun State, Nigeria. However, this study's findings can represent other firms in other locations where TPM is practiced. This research will be helpful for FMCG firms in Nigeria, especially those in Ogun State. TPM was measured using the following indicators: 5S, Autonomous Maintenance, Kobetsu Kaizen, Planned Maintenance, Quality, Education and Training, Office TPM, and Health, Safety and Environment. Eight indicators measure The company's performance: Product Quality, Cost, Inventory, Lead Time, Processing Cycle Time, Customer Complaints, Equipment Efficiency and Overall Productivity. The research review shows that the TPM implementation significantly affects firms' sustainable performance. In addition, the result shows that local firms in the survey area are yet to key into implementing TPM practices fully.

A Systematic Literature Review of Total Productive Maintenance On Industries

Attempts to achieve optimization of machine and equipment maintenance at manufacturing companies over the years have encountered a multitude of problems. Due to equipment losses such as setup and adjustment, minor stops and delays, defective products due to equipment, reduced engine speed, and reduced output has influenced their desire to reach world class manufacturing levels. This paper discusses a large part of the TPM approach in manufacturing companies and provides an overview of the various TPM implementation practices demonstrated by manufacturing companies in the world.. Based on review results of the 50 journals about TPM in industries It was found that most of the TPM implementations used the OEE parameter to see the success rate of implementing this TPM. This paper also highlights the variable approach that is most widely used by various practitioners and researchers and evaluates in detail the success factors of implementing TPM and the reasons behind the failure of implementing TPM are also discussed so as to ensure the implementation of TPM can run smoothly and effectively in manufacturing companies

Identification of total productive maintenance barriers in Indian manufacturing industries

Every manufacturing industry are much concerned with their maintenance strategies adopted on the shop-floor to avoid breakdowns. As breakdowns directly leads to lowering the capacity utilization thus results in poor productivity. Recently, Total Productive Maintenance has emerged as one of the robust maintenance strategies and many big industries has adopted it in their work culture. Still, Indian manufacturing sector is not much familiar with the sustainable benefits of TPM and also hesitant to deploy TPM across their unit. In past, many manufacturing units has tried TPM but they are failing due to lack of knowledge base available on the barriers related to its successful implementation. The main goal of this study is to find key barriers related to TPM implementation across Indian manufacturing. A vast literature has been explored and potential barriers have been extracted that hinders the TPM performance in Indian context. Further, importance index has been compute based on expert opinion to find out most significant barriers of TPM implementation. Present results will provide the manufacturing managers the prominent barriers that can be tackled at early stage and will lead to successful execution of TPM across the unit.

Maintenance Plan Based on TPM for Turbine Recovery Machinery

The maintenance and repair of the components of hydroelectric turbines require the use of specialized equipment. To keep these teams operational, it is proposed to design a master plan in order to develop a TPM philosophy for a vertical turning lathe. This project develops five of the twelve steps established by JIPM for the TPM implementation. This paper also provides the necessary documentation for 5S and autonomous maintenance applications. Also, some safety, health and environmental suggestions are provided. PM activities are chosen based on RCM techniques like CA and FMEA. And predictive maintenance activities are established following ISO 3655, 2006. All these activities including automotive maintenance ones are organized and scheduled. Finally, OEE rate is applied to the lathe to identify the principal losses on the machine. After applying this proposal there is an increase of 27.84% and 39.71% in availability and performance respectively. The OEE calculation has increased by 29.97%, thereby motivating readers to implement this methodology in other industries.

In India, there is a link between TQM and TPM implementation elements and manufacturing sector business performance

In India, there is a link between TQM and TPM implementation elements and manufacturing sector business performance

Analytical evaluation of TPM performance based on an economic criterion

PurposeTotal productive maintenance (TPM) has been widely recognized as a strategic weapon for improving manufacturing performance. Evaluate efficiency of TPM implementation is considered as a key element in order to motivate staff and to give decision-makers more confidence.Design/methodology/approachThis study consists in developing a new method of evaluating TPM implementation, relying on analytical models and considering two preventive maintenance strategies: periodic and age-dependent.FindingsThe preventive maintenance period and TPM period defined as decision variables are obtained simultaneously by maximizing the expected profit under TPM implementation. A numerical example is presented and a sensitivity study is developed to validate the proposed models.Originality/valueThe aim of this research is to quantify, through analytic development, the impact of TPM implementation in a company by calculating and comparing the profit made with and without TPM.

Perception of Employees towards TPM implementation in Foundry Industry with Reference to Coimbatore District

Perception of Employees towards TPM implementation in Foundry Industry with Reference to Coimbatore District

Improvement in productivity through TPM Implementation

The Plastic moulding injection industry has undergone substantial variations in the last few years. The struggle has increased dramatically. Consumers concentrates on the product of quality, product cost and delivery time of the product. Because of that, organization should introduce a system of quality to advance and upsurge both productivity and quality progressively. TPM is an approach that targets to upsurge the accessibility of present instruments and therefore lowering the necessity for next capital involvement. Investment in human assets shows better hardware consumption, better product quality and lesser labour costs. Objective of the paper is to analyze the usefulness and application of the TPM plan for an automotive injection moulding parts manufacturing company. By implementing TPM in an automotive injection moulding parts manufacturing company, the practical characteristics inside and beyond basic TPM theory, problems in the acceptance of TPM and the problems faced during the execution are discussed and analysed.

Justification of TPM pillars for enhancing the performance of manufacturing industry of Northern India

PurposeThe purpose of this paper is to assess TPM pillars for manufacturing performance improvement in the manufacturing organizations of Northern India and to identify critical and non-critical components based on failure history, to minimize machine downtime, maximize component/machine availability and to identify failure modes, their causes and effects of these failures on machines or components in the case company under study.Design/methodology/approachIn this paper, TPM pillars in the paint 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.FindingsFindings suggest that maintenance planning is more effective than small improvements for achieving benefits from TPM pillars. Moreover, results indicated that critical components show average reliability and failure probability of about 50 percent.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 implementation in the manufacturing plant, which can also be important to all concerned with maintenance in various manufacturing enterprises.

Tpm Safety Impact – Case Study

Abstract The global production companies of today are exposed to increasingly stronger pressure to implement new technologies, improve quality and decrease production costs. All this is related to ensuring a proper technical condition of machines and devices. This article presents the results of an analysis of the impact of implementation of TPM at the rolling mill on work safety. The number of near misses and accidents was used as a measure of the safety level.

TPM implementation requirements and developing a TPM implementation methodology for an educational institution: a case study

The TPM implementation for a technical educational institute is a concept which focuses on the upkeep of technical equipment and the continuous improvement of the teaching and learning environment. The aim is to ensure the conduct of effective and efficient training in workshops and laboratories. The philosophy of TPM implementation focuses on the training process, technical equipment, workplace environment and people. Therefore, the institute management must focus on obtaining, maintaining and managing the resources and organisational culture. Quality of training can only be achieved once all the resources are available and in balance. By focusing training on the maintenance and promoting an environment that supports teamwork, project work, open communication and problem-solving, institutional managers and staff, establish a work culture that is necessary for the implementation of the MMS philosophy. The paper focuses on the understanding institution scenario and the TPM implementation requirements in the institute and identifying the areas and developing the methodology for the implementation.

TPM implementation requirements and developing a TPM implementation methodology for an educational institution: a case study

TPM implementation requirements and developing a TPM implementation methodology for an educational institution: a case study

Performance analysis of TPM implementation through Overall Equipment Effectiveness (OEE) and Six Big Losses

PT. TMI is a company engaged in the field of automotive that has implemented Total Productive Maintenance to improve efficiency and effectiveness of manufacturing companies as a whole. But it turns out that targets that are not achieved still often occur due to engine trouble. This study aims to determine the maintenance system of Press 2A machine that has a high rate of decline in speed. This study begins by measuring the achievement of Overall Equipment Effectiveness (OEE) value by first calculating the Availability, Performance Rate and Rate of Quality, then identifying the Six Big Losses that occur. The results showed that the average value of OEE on 2A Stamping machine is 70%, the effectiveness value is moderate and still below the standard of OEE value for world class company that is 85%. While the factor of Six Big Losses most influential on the low effectiveness of Press 2A machine is Reduced Speed Loss with total loss for a year of 56.411 minutes or 53% of all losses.

The Role of Managerial Commitment and TPM Implementation Strategies in Productivity Benefits

The present research proposes a structural equation model to integrate four latent variables: managerial commitment, preventive maintenance, total productive maintenance, and productivity benefits. In addition, these variables are related through six research hypotheses that are validated using collected data from 368 surveys administered in the Mexican manufacturing industry. Consequently, the model is evaluated using partial least squares. The results show that managerial commitment is critical to achieve productivity benefits, while preventive maintenance is indispensable to total preventive maintenance. These results may encourage company managers to focus on managerial commitment and implement preventive maintenance programs to guarantee the success of total productive maintenance.

Eliminating Obstacles in TPM Implimentation In Sugarmill Industry

In the dynamic scenario of technology, many technological innovations are available to contribute in the analysis of Equipment Efficiency, minimized input v/s optimized output, minimizing the overall consumption, effective use of machineries and finally increase in production rate by expenditure and consumption of sources. Since the starting of technological era, Scientists/ Researchers have put mammoth efforts to increase production rate. To embark with, many small inadequacies of equipments and machines can lead to the huge losses in small to medium scale industries. Implementation of TPM in various industries has contributed its effective role but not much work available with small to medium scale sugar mill industries in India.In Ajnala Cooperative Sugar Mill, Amritsar, the author has contributed that the mill management avoid doing the changes with traditional approaches of productivity for example changes in setup and maintenance scheduling. So to remove the obstacles, the author has suggested several steps to bring the minimum but necessary changes in maintenance and repairs. The author made an attempt to increase the Overall Equipment Efficiency and to decrease the high rejection rate, downtime, and setup time to compete with others similar industries by applying Total Productive Maintenance in the small scale industry by eliminating the upcoming obstacles successfully.

Application of AHP for Ranking of Total Productive Maintenance Pillars

Total Productive Maintenance—TPM is widely being used in industries for manufacturing excellence. TPM is based on its eight pillars. Successful Implementation of TPM from its kick-off to final stage depends on in-depth knowledge of these pillars. The purpose of the paper is to rank eight pillars of TPM according to their importance with respect to four parameters: Productivity, Cost, Quality and Delivery in Time, by using Analytic Hierarchy Process (AHP) a multiple criteria decision-making methodology. A pairwise comparison of TPM pillars is done by use of AHP method, by considering a case of automotive industries in India. Ranking of TPM pillars is proposed to set guidelines to decide the weightage of each pillar in terms of major factors to improve Overall Equipment Efficiency. This in terms will guide management to give proper preference and allocate fund at proper time to proper pillar. The ranking suggested suites for automotive sector and assembly lines. By varying the judgmental rating the new ranking can be obtained from the suggested guidelines on similar basis.

Ethical and psychological factors in 5S and total productive maintenance

Purpose: The purpose of this paper is to investigate the role of ethical and psychological factors in the implementation of 5S and TPM at cement plants in Kurdistan Region of Iraq.Design/methodology/approach: The mixed methods represented in a questionnaire survey and semi-structured interviews for data collection in the framework of the case study were chosen. The questionnaire survey already has been tested.Findings: The findings of this paper revealed that ethical factors had a larger role than psychological factors in the implementation. Thus, based on the findings, organisations are recommended to provide financial and moral support to employees to enable a comprehensive implementation of 5S and TPM aimed at obtaining the desired results. Originality/value: The current paper tried to introduce a new theoretical contribution by filling the gap in the literature regarding the important role that can be played by ethical and psychological factors of employees in the successful implementation of contemporary techniques, such as 5S and TPM in industrial organizations. This is contrary to what was done most of previous studies such as Ahuja & Khamba, (2008b) Panneerselvam (2012) Singh et al. (2013) and Poduval & Pramod (2015) in the area of 5S and TPM. Where, these studies have focused on studying the other factors such as (organizational, technological, operational and others) in implementing 5S and TPM. This without realizing the fact that it is also necessary to examine factors such as (ethical and psychological) that would affect the capabilities and employee morale before and during the implementation of those techniques (5S and TPM) that are used to bring out the best productivity.