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Article
Publication date: 14 September 2012

Sanjiv Kumar Jain and Inderpreet Singh Ahuja

The purpose of this paper is to evaluate the contributions of ISO 9000 initiatives towards improving manufacturing performance in the Indian manufacturing industry.

Abstract

Purpose

The purpose of this paper is to evaluate the contributions of ISO 9000 initiatives towards improving manufacturing performance in the Indian manufacturing industry.

Design/methodology/approach

In this study, 96 manufacturing organizations have been extensively surveyed, to ascertain contributions made by ISO 9000 initiatives in the Indian manufacturing industries towards realizing manufacturing performance improvements. The correlations between various ISO 9000 implementation issues and manufacturing performance improvements have been evaluated and validated by employing various statistical tools.

Findings

The research focuses on the significant contributions of ISO 9000 implementation success factors like top management contributions, continuous improvement practices and ISO 9000 implementation initiatives, towards affecting improvements in manufacturing performance in the Indian industry. The inter‐relationships between various ISO 9000 implementation success factors with the manufacturing performance improvement parameters have been evaluated, to efficiently manage the ISO 9000 implementation program to realize organizational objectives of growth and sustainability.

Research limitations/implications

The study establishes that focused ISO 9000 implementation over a reasonable time period can strategically contribute towards realization of significant manufacturing performance enhancements.

Practical implications

The study stresses the need for improving the coordination between manufacturing function and other organizational quality improvement initiatives in the organizations, to establish manufacturing as a competitive strategy for meeting the challenges of highly competitive environments.

Social implications

The findings suggest that effective ISO 9000 initiatives can significantly contribute towards realization of strategic manufacturing performance improvements for competing in the highly dynamic global marketplace. These interrelationships can be used to understand the effect of various ISO 9000 success factors towards realization of organization objectives of growth and sustainability.

Originality/value

The study highlights the strong potential of ISO 9000 implementation initiatives in affecting organizational performance improvements. The achievements of Indian manufacturing organizations through proactive ISO 9000 initiatives have been evaluated and critical ISO 9000 success factors identified for enhancing the effectiveness of ISO 9000 implementation programs in the Indian context.

Details

International Journal of Productivity and Performance Management, vol. 61 no. 7
Type: Research Article
ISSN: 1741-0401

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Article
Publication date: 25 January 2008

I.P.S. Ahuja and J.S. Khamba

The purpose of this paper is to evaluate the contributions of total productive maintenance (TPM) initiatives towards improving manufacturing performance in Indian…

Abstract

Purpose

The 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/approach

In 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.

Findings

The 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/implications

The study establishes that focused TPM implementation over a reasonable time period can strategically contribute towards realization of significant manufacturing performance enhancements.

Practical implications

The 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/value

The 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.

Details

International Journal of Quality & Reliability Management, vol. 25 no. 2
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 13 March 2017

Lai Wan Hooi and Tat Yuen Leong

The purpose of this paper is to examine the multidimensionality of total productive maintenance (TPM) and its relationship with manufacturing performance improvement in…

Abstract

Purpose

The purpose of this paper is to examine the multidimensionality of total productive maintenance (TPM) and its relationship with manufacturing performance improvement in the Malaysian manufacturing sector. Specifically, this study evaluates the contribution of each TPM success factors in improving manufacturing performance.

Design/methodology/approach

Data from 89 employees who participated in the survey were used to test the proposed research framework. A structured questionnaire adopted from Ahuja and Khamba (2006) was used to assess the Malaysian context.

Findings

The analytical results reveal that traditional maintenance initiatives and TPM implementation initiatives significantly affect manufacturing performance, but not top management leadership and maintenance organisation. Top management roles and commitment are critical in the early stage to determine the master plan and initiate the implementation of the whole programme. However, traditional maintenance and TPM implementation initiatives gradually enable engagement, proper planning, right execution and continuous improvement, ultimately improving the manufacturing performance indicators significantly. The findings further unveil that TPM is not sustainable in Malaysia’s manufacturing organisations in the long run.

Practical implications

This analysis is vital for senior managers of manufacturing organisations that have implemented TPM or are considering introducing TPM in their organisations.

Originality/value

This study contributes to the literature by examining beyond the introduction and stabilisation phase of TPM to provide an insight of whether TPM is sustainable in the long run.

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Article
Publication date: 5 June 2017

Jagdeep Singh Sraun and Harwinder Singh

The purpose of this paper is to investigate the contributions of successful continuous improvement (CI) strategic implementation to competitive manufacturing. It also…

Abstract

Purpose

The purpose of this paper is to investigate the contributions of successful continuous improvement (CI) strategic implementation to competitive manufacturing. It also seeks to critically examine the level of importance of CI strategy implementation in Indian manufacturing organizations.

Design/methodology/approach

A reasonably large number of manufacturing organizations with successful experience of CI approach have been surveyed to assess the contributions of CI strategies and approach towards accruing useful benefits. The study involves working out the correlations between various CI strategies and manufacturing performance parameters to ascertain the contributions of significant strategies towards realization of manufacturing performance improvement.

Findings

The results of investigation demonstrated that CI strategies and approach significantly aimed at improving the quality of product manufactured by small- and medium-scale manufacturing enterprises. Supportive tools have negative impact on manufacturing performance parameters. Total productive maintenance strategies have highly significant impact on manufacturing performance improvement.

Practical implications

The study establishes that CI strategic implementation can systematically contribute towards realization of significant manufacturing performance enhancements.

Originality/value

The study highlights both positive and negative potentials of CI strategic implementation affecting performance improvements. The achievements of Indian manufacturing organizations through proactive CI approach have been evaluated and the critical impact of CI strategies has been identified for enhancing the effectiveness of CI activities in the Indian context.

Details

International Journal of Lean Six Sigma, vol. 8 no. 2
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 1 August 2008

I.P.S. Ahuja and J.S. Khamba

The purpose of this paper is to review the literature on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices adopted by the…

Abstract

Purpose

The purpose of this paper is to review the literature on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices adopted by the manufacturing organizations. It also seeks to highlight appropriate enablers and success factors for eliminating barriers in successful TPM implementation.

Design/methodology/approach

The paper systematically categorizes the published literature and then analyzes and reviews it methodically.

Findings

The paper reveals the important issues in Total Productive Maintenance ranging from maintenance techniques, framework of TPM, overall equipment effectiveness (OEE), TPM implementation practices, barriers and success factors in TPM implementation, etc. The contributions of strategic TPM programmes towards improving manufacturing competencies of the organizations have also been highlighted here.

Practical implications

The literature on classification of Total Productive Maintenance has so far been very limited. The paper reviews a large number of papers in this field and presents the overview of various TPM implementation practices demonstrated by manufacturing organizations globally. It also highlights the approaches suggested by various researchers and practitioners and critically evaluates the reasons behind failure of TPM programmes in the organizations. Further, the enablers and success factors for TPM implementation have also been highlighted for ensuring smooth and effective TPM implementation in the organizations.

Originality/value

The paper contains a comprehensive listing of publications on the field in question and their classification according to various attributes. It will be useful to researchers, maintenance professionals and others concerned with maintenance to understand the significance of TPM.

Details

International Journal of Quality & Reliability Management, vol. 25 no. 7
Type: Research Article
ISSN: 0265-671X

Keywords

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Article
Publication date: 16 August 2019

Saumyaranjan Sahoo

The purpose of this paper is to provide sector-specific empirical evidence on the comparative evaluation of total productive maintenance (TPM) and total quality management…

Abstract

Purpose

The purpose of this paper is to provide sector-specific empirical evidence on the comparative evaluation of total productive maintenance (TPM) and total quality management (TQM) approaches, implemented exclusively and collectively on improving manufacturing business performance.

Design/methodology/approach

This paper develops a multi-sector analysis framework to comparatively assess the synergistic and standalone effect of TPM and TQM improvement approaches. A total of 231 manufacturing organizations from food and beverages, textiles and electrical and electronics sectors have been extensively surveyed. These firms were further clustered into TPM focus, TQM focus and integrated TPM×TQM on the basis of their primary manufacturing strategy. Comparative assessment of these three manufacturing approaches has been evaluated using t-test statistics.

Findings

This paper highlights that adoption of integrated TPM×TQM approach is beneficial for food and beverages and electrical and electronics sectors. However, this supposition is rejected for firms operating in the textile sector.

Research limitations/implications

The findings of this research are still exploratory. Future research using countrywide and cross-country approach can be undertaken to statistically generalize the findings of the present research. In-depth case studies are needed to further validate the findings of the study empirically.

Practical implications

The result of this study help managers and practitioners to make manufacturing strategic decision based on the nature of their operating business sector regarding adoption of TPM and TQM practices, which will further revive their firm’s competitiveness.

Originality/value

Every operating sector embraces a diversity of manufacturing activities based upon their competing priorities. This paper makes an attempt to present a multi-sectoral evaluation of joint implementation and effect of manufacturing programs.

Details

Journal of Quality in Maintenance Engineering, vol. 25 no. 3
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 5 November 2018

Saumyaranjan Sahoo

The purpose of this paper is to comparatively assess the contributions of total quality management (TQM) and total productive maintenance (TPM) practices, exclusively and…

Abstract

Purpose

The purpose of this paper is to comparatively assess the contributions of total quality management (TQM) and total productive maintenance (TPM) practices, exclusively and collectively, on manufacturing business performance.

Design/methodology/approach

Responses to survey questionnaires were collected using multiple modes of data collection. A total of 269 filled responses were collected and analyzed to ascertain the contribution made by exclusive and collective implementation of TQM and TPM practices on business performance. The respondent firms were grouped into three clusters based on early, in-transition and advanced stages of implementation of either or both TQM and TPM manufacturing practices. Comparative assessment of the impact of standalone TQM, standalone TPM and combined TQM–TPM manufacturing methods on business performance parameters have been evaluated using statistical tools within each cluster.

Findings

Evidences were found to support the supposition that integrated implementation of both TQM and TPM practices over a reasonable period of time contributes in delivering better business performance as compared to the standalone implementation strategy.

Research limitations/implications

The study has its own limitations because of its chosen research approach. As the data in this study were collected from production management personnel on the basis of their subjective evaluations, more comprehensive objective performance indicators shall be employed for comparative assessment of manufacturing practices in future studies. In-depth case studies are needed to further validate the findings of the research study.

Practical implications

The analytical results reveal that an integrated TQM–TPM strategic implementation can systematically contribute toward realization of significant improvement in manufacturing business performance parameters. The results of this study are vital for production managers and senior management personnel of manufacturing firms that have implemented TQM and are considering introducing TPM in their organization (or vice-versa).

Originality/value

This empirical study signifies the need for strategically aligning and managing various production improvement ideologies for realization of an organization’s growth and sustainability in a long run. In particular, this paper invigorates the discussion about improving the synergy between maintenance and quality functions in the organization for meeting the challenges of highly competitive market environment.

Details

Journal of Manufacturing Technology Management, vol. 29 no. 7
Type: Research Article
ISSN: 1741-038X

Keywords

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Article
Publication date: 22 May 2009

Yinan Qi, Chee‐Chuong Sum and Xiande Zhao

The purpose of this paper is to examine the simultaneous effects of two process variables: functional involvement in strategy formulation, and manufacturing improvement

Abstract

Purpose

The purpose of this paper is to examine the simultaneous effects of two process variables: functional involvement in strategy formulation, and manufacturing improvement programs, on manufacturing performance and financial performance of manufacturing firms in China.

Design/methodology/approach

Rigorous empirical research methods are used to ensure proper data collection process, and reliability and validity of constructs. Structural equation modeling is used to examine the relationships between functional involvement, improvement programs, manufacturing performance and financial performance.

Findings

It was found that involvement of marketing, finance and operations in strategy formulation have an effect on cost and quality whereas the involvement of emerging functions such as human resources, public relations, research and development and information technology have an effect on all aspects of manufacturing performance.

Originality/value

Studies of manufacturing strategy have primarily focused on choices and plans that denote strategic intent, rather than on the process of formulating and realizing strategy. Typical studies have used data from developed countries, such as Europe and North America. Insufficient attention has been paid to the process variables of manufacturing strategy and their effects on manufacturing performance. The study addresses these gaps in the literature using data collected from Chinese firms.

Details

International Journal of Operations & Production Management, vol. 29 no. 6
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 2 October 2007

I.P.S. Ahuja and J.S. Khamba

The purpose of this study is to identify maintenance‐related losses for ascertaining and addressing the performance losses, and affecting improvements in the manufacturing

Abstract

Purpose

The 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/approach

In 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.

Findings

The 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 implications

This 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/value

The 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.

Details

Journal of Quality in Maintenance Engineering, vol. 13 no. 4
Type: Research Article
ISSN: 1355-2511

Keywords

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Article
Publication date: 23 February 2020

Saumyaranjan Sahoo

The purpose of the paper is to examine the impact of human-related support practices, total productive maintenance (TPM) practices, and total quality management (TQM…

Abstract

Purpose

The purpose of the paper is to examine the impact of human-related support practices, total productive maintenance (TPM) practices, and total quality management (TQM) practices on manufacturing performance parameters and their inter-relationship.

Design/methodology/approach

A research project was carried out in 94 Indian manufacturing companies, using the questionnaire method. The survey data was drawn from 169 respondents working in these companies. In this paper, the impact of TPM and TQM practices on manufacturing performance parameters and especially the role of support practices is investigated empirically using various structural equation models.

Findings

Two factors namely top management and leadership and human resource development categorized as support practices were found to positively influence the adoption of technical practices, i.e., TPM and TQM practices. Hence support practices were found to indirectly affect the manufacturing performance parameters via the technical factors. Also analyzing various structural equation models (SEM), shop floor implementation of TPM practices were found to be influenced (or guided) by the philosophy of TQM practices. In other words, through the proper adoption of TQM practices, the effectiveness of TPM practices gets increased.

Research limitations/implications

Because of the chosen research approach, the research results may lack generalizability. Therefore, researchers are encouraged to test the proposed propositions further using a case study approach.

Practical implications

The present study provides useful insights to practicing managers. The result of the study explaining the interrelationship between support practices (behavioral aspect) and technical practices can be used by practicing managers to develop a better understanding of the contribution of support and technical practices towards the realization of organizational objectives of growth and sustainability. In practice, TQM plays a great role in the adoption of TPM practices, which in turn helps to achieve quality in processes and therefore in products.

Originality/value

Previous research has often either concentrated on technical practices as one dimension without studying the effects of support practices on improving the adoption of technical practices. The results of the study take one step further by investigating the relationship between multiple aspects (support and technical aspects) of manufacturing practices and their impact on manufacturing performance.

Details

Benchmarking: An International Journal, vol. 27 no. 4
Type: Research Article
ISSN: 1463-5771

Keywords

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