Search results

1 – 10 of over 12000
Article
Publication date: 7 April 2022

André Luís Castro Moura Duarte and Marcia Regina Santiago Santiago Scarpin

This study aims to identify the relationship between different maintenance practices and productive efficiency in continuous process productive plants as well as the moderating…

Abstract

Purpose

This study aims to identify the relationship between different maintenance practices and productive efficiency in continuous process productive plants as well as the moderating effect of good training practices.

Design/methodology/approach

The empirical data were drawn from a database containing 609 observations of 29 productive units. Scales were validated using the Q-sort method. The panel data technique was used as the analysis methodology, with the inclusion of fixed effects for each productive plant.

Findings

Maintenance practices can effectively contribute to increasing the overall equipment effectiveness (OEE) of firms. Application of predictive maintenance practices should be considered as the primary training tool.

Research limitations/implications

This study used a secondary database, limiting the research design and data manipulation.

Practical implications

The article provides practitioners with an analysis of maintenance practices by category (predictive, preventive and corrective), and the impact of each practice on the OEE of continuous process productive plants. Moreover, it explores the importance of training for extracting more results from maintenance practices.

Social implications

Companies are investing in new technologies, but it is also essential to invest in training people. There is a demand for Industry 4.0 through the introduction of upskilling and reskilling programs.

Originality/value

This study used practice-based view (PBV) theory to explain how maintenance practices help firms achieve greater OEE. Furthermore, it introduced training practice as a moderating variable in the relationship between maintenance practices and OEE.

Details

Journal of Quality in Maintenance Engineering, vol. 29 no. 2
Type: Research Article
ISSN: 1355-2511

Keywords

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 manufacturing…

15439

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

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 the…

4861

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.

Article
Publication date: 3 October 2008

Heiko Gebauer, Felix Pützr, Thomas Fischer, Chunzhi Wang and Jie Lin

The purpose of this paper is to explore maintenance strategies for manufacturing equipment in Chinese firms.

1401

Abstract

Purpose

The purpose of this paper is to explore maintenance strategies for manufacturing equipment in Chinese firms.

Design/methodology/approach

Data were collected from Chinese companies using a questionnaire administered during face‐to‐face interviews and two established methodologies in strategic management research, exploratory factor analysis and cluster analysis, were used to analyze the data.

Findings

The results suggest that despite increasing competitive capabilities of Chinese firms, their maintenance strategies are often restricted to corrective maintenance. Only very few Chinese firms have already implemented predictive maintenance approach, total productive maintenance programs or the strategic outsourcing of maintenance activities.

Research limitations/implications

The research limitations stem from typical issues related to the use of exploratory factor analysis and cluster analysis (for example reliance on the subjective judgment of the researcher or the provision of clusters although no meaningful groups are embedded in the sample).

Practical implications

The findings highlight potential strategies for Chinese firms to improve their maintenance management.

Originality/value

This paper deals with a neglected area of operations management by exploring the maintenance approaches in fast growing Chinese manufacturing industries.

Details

Management Research News, vol. 31 no. 12
Type: Research Article
ISSN: 0140-9174

Keywords

Article
Publication date: 29 July 2014

Abhishek Jain, Rajbir Bhatti and Harwinder Singh

The purpose of this paper is to review the literature on total productive maintenance (TPM) implementation practice to present an overview of TPM implementation practices adopted…

4378

Abstract

Purpose

The purpose of this paper is to review the literature on total productive maintenance (TPM) implementation practice to present an overview of TPM implementation practices adopted by various manufacturing organizations and suggest possible gaps from researchers and practitioner’s point of view. This study tries to identify the best strategy for improving competitiveness of small and medium enterprises (SMEs) in globalized market and evaluates TPM implementation practice in SMEs.

Design/methodology/approach

The objective of this paper is to study the role of TPM program in context of Indian industries either from SMEs to large-scale industries. The approach has been directed toward justification of TPM implementation practice for its support to competitive manufacturing in the context of Indian manufacturing industries.

Findings

TPM implementation improves productivity and working efficiency of employees and also improves equipment effectiveness and a positive inclination toward company is registered. Therefore, equipment maintenance is an indispensable function in a manufacturing enterprise. In this highly competitive environment, manufacturing organizations should consider maintenance function as a potential source for cost savings and competitive advantage. SMEs must be considered as an engine for economic growth all over the world (Singh et al., 2008). A total of 148 papers related to TPM implementation in large-scale industries and SMEs were collected, analyzed and classified on the basis of their applications, broadly into large industry and SMEs and further divided into Indian and Non-Indian, then case study, implementation, model, literature review, maintenance, service, etc. This classification has clearly shows that SMEs are in a need to adopt TPM implementation practice to compete in this global market and changing requirements of large industries. Maintenance is an indispensable function in a manufacturing enterprise. In this highly competitive environment, manufacturing organizations must be considered maintenance function as a potential source for cost savings and competitive advantage. Singh et al. (2008) have concluded that SMEs must be considered as an engine for economic growth of all over the world. Following are the objectives of this study: to suggest a classification of available literature on TPM implementation; to identify the need of TPM implementation in SMEs; to identify critical observations on each category of classification; to identify the potential of SMEs in India; to identify emerging trends of TPM implementation in India; to suggest directions for future researchers in the field of TPM implementation on the basis of above mention points; and to consolidate all available literature on TPM implementation practice.

Research limitations/implications

The challenges of stiff competition and the drive for profits are forcing the organizations to implement various productivity improvement efforts to meet the challenges posed by ever-changing market demands. In the dynamic and highly challenging environment, reliable manufacturing equipment is regarded as the major contributor to the performance and profitability of manufacturing systems.

Practical implications

In this dynamic world, importance of SMEs in the growth of the nation needs more attention of researchers and industrialists. After the globalization of market, SMEs have got many opportunities to work in integration with large-scale organizations. All the organizations from SMEs to large-scale industries can adopt effective and efficient maintenance strategies such as condition-based maintenance, reliability-centered maintenance and TPM over the traditional firefighting reactive maintenance approaches (Sharma et al., 2005).

Social implications

In our view, this paper clearly identifies implications for research which will be useful for society. The gap discussed by authors needs to be addressed by future researchers.

Originality/value

This implementation strategy can help to save huge amounts of time, money and other useful resources in dealing with reliability, availability, maintainability and performance issues. On the basis of available literature, it can be understood that SMEs should change their maintenance strategies to cope up with global competition so that a lot of resources can be utilized in a better direction.

Details

International Journal of Lean Six Sigma, vol. 5 no. 3
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 22 September 2023

Mulatu Tilahun Gelaw, Daniel Kitaw Azene and Eshetie Berhan

This research aims to investigate critical success factors, barriers and initiatives of total productive maintenance (TPM) implementation in selected manufacturing industries in…

Abstract

Purpose

This 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/approach

This 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.

Findings

According 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/implications

The 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 implications

Defining 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/value

This 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.

Details

Journal of Quality in Maintenance Engineering, vol. 30 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 1 September 1999

C.J. Bamber, J.M. Sharp and M.T. Hides

Modern manufacturing requires that to be successful organisations must be supported by both effective and efficient maintenance. One approach to improving the performance of…

9308

Abstract

Modern manufacturing requires that to be successful organisations must be supported by both effective and efficient maintenance. One approach to improving the performance of maintenance activities is to implement and develop a total productive maintenance (TPM) strategy. However, it is well documented that a number of organisations are failing to successfully implement such strategies. This paper outlines research carried out by the Aeronautical, Mechanical and Manufacturing Engineering Department at Salford University aimed at discovering the factors affecting the successful implementation of TPM. This research has led to the development of a generic model indicating factors affecting the successful implementation of TPM. The validity of the generic model has been tested in a UK manufacturing small‐ to medium‐size enterprise (SME) and the case study research findings further triangulated through a review of documented case study evidence. This research has also led to the development of recommendations to improve the TPM development and implementation program of the case study organisation. Further development of the research has resulted in a step‐wise program or generic roadmap for UK SMEs which is proposed as a tool for the implementation or rejuvenation of an organisation’s TPM program.

Details

Journal of Quality in Maintenance Engineering, vol. 5 no. 3
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 15 August 2008

Andrew Thomas, Richard Barton and Paul Byard

Both total productive maintenance (TPM) and Six Sigma are key business process strategies, which are employed by companies to enhance their manufacturing performance. The purpose…

3168

Abstract

Purpose

Both total productive maintenance (TPM) and Six Sigma are key business process strategies, which are employed by companies to enhance their manufacturing performance. The purpose of this paper, therefore, will be to develop and implement an integrated Six Sigma maintenance (SSM) model for manufacturing industry

Design/methodology/approach

Through the development of a case study approach, the paper chronicles the design, development and implementation of an integrated Six Sigma maintenance (SSM) model. The model is subsequently evaluated for its effectiveness in the subject company.

Findings

A model is proposed and the effectiveness of the approach is subsequently evaluated highlighting the benefits the host organization received through this new approach by measuring the effects of implementation against the seven quality, cost and delivery (QCD) measures.

Practical implications

The design, development and implementation of a Six Sigma maintenance model shown in this paper provides a simple yet highly effective approach to achieving significant improvements in a company's product quality cost and delivery measures. The model combines contemporary business management techniques with total productive maintenance strategies and offers practicing maintenance managers and engineers a strategic framework for increasing productive efficiency and output.

Originality/value

The proposed SSM model contributes to the existing knowledge base on maintenance systems and subsequently disseminates this information in order to provide impetus, guidance and support towards increasing the development companies in an attempt to move the UK manufacturing sector towards world class manufacturing performance.

Details

Journal of Quality in Maintenance Engineering, vol. 14 no. 3
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 10 October 2016

Sachin Modgil and Sanjay Sharma

The purpose of this paper is to investigate the impact of total productive maintenance (TPM) and total quality management (TQM) practices on operational performance and their…

5237

Abstract

Purpose

The purpose of this paper is to investigate the impact of total productive maintenance (TPM) and total quality management (TQM) practices on operational performance and their inter-relationship.

Design/methodology/approach

The present study includes three main constructs, namely, TPM, TQM and operational performance of pharmaceutical industry. Under TPM, four constructs, namely, disciplined maintenance, information tracking, housekeeping and operator involvement has been considered with the help of literature. In TQM, four constructs, namely, quality data and reporting, product innovation, research and development (R&D) management and technology management has been considered. Out of 410 Indian pharmaceutical plants contacted for survey, 254 responses have been used in the study for analysis. The factor analysis, path model and structural equation modeling has been used to analyze the proposed framework. The results for alternate models has been studied, interpreted and reported. Finally the direct and indirect effect of TPM and TQM on operational performance has been tested and checked for proving and disproving the hypotheses.

Findings

TPM practices have a significant impact on plant-level operational performance. When TPM and TQM practices are coming together to achieve operational performance, then TPM is having strong influence on operational performance. TQM is having significant support from TPM to achieve operational performance. TPM impact TQM and TQM in turn helps to achieve operational performance. TPM practices impact significantly R&D, product innovation and technology management, whereas quality data and reporting is the least contributor toward TQM. This may help industry to understand implications of implementation of TPM and TQM to achieve plant-level operational performance. TPM will help to reduce the cost of quality in terms of reduced scrap and less defective products.

Practical implications

The present study provides the useful insights to practicing managers. In literature it has been mentioned that TQM helps in TPM implementation. In practice TPM plays a great role to achieve quality in processes and therefore in products. In turn quality products, with reduced work in process inventory, less defective products and reduced scrap helps to achieve the operational performance at plant level. TPM practices will help the organization to improve the pace of product innovation and improvement in productivity, which is critical to pharmaceutical industry. The continuous monitoring of TPM practices can help organizations to run day to day operations and maintenance requirement of each machine over a specified period of time.

Originality/value

The present study diagnoses the inter-dimensional linkage between TPM, TQM and operational performance. The pharmaceutical industry is complex system of advance equipment’s and processes. After human resources, the health of machines/equipment’s describe the strength of an organization. The machines require the regular maintenance to produce the products with desired specifications. The specifications in medicines and very tight, which can be achieved only if machines/testing equipment’s are updated and maintained regularly. The TPM practices will helps the plants to achieve the operational performance by having quality in processes.

Details

Journal of Quality in Maintenance Engineering, vol. 22 no. 4
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 30 May 2008

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

The purpose of this study is to evaluate the challenges before Indian manufacturing organizations for adapting to proactive total productive maintenance (TPM) initiatives. The aim…

4909

Abstract

Purpose

The 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/approach

The 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.

Findings

The 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/implications

The 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 implications

The 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/value

The study highlights the difficulties faced by Indian manufacturing organizations in their attempt to implement TPM initiatives in order to improve organizational efficiency.

Details

Journal of Quality in Maintenance Engineering, vol. 14 no. 2
Type: Research Article
ISSN: 1355-2511

Keywords

1 – 10 of over 12000