A sequential TPM-based scheme for improving production effectiveness presented with a case study

Abstract

Purpose The purpose of this paper is to improve production effectiveness of equipment by facilitating the implementation of the key principles of total productive maintenance (TPM). Design/methodology/approach A sequential TPM-based scheme consisting of 13 procedural steps is proposed. The steps cover the basic aspects of a generic improvement system, i.e. planning, implementation, checking, corrective action and control. Findings The proposed scheme was effective in increasing the overall equipment effectiveness by 62.6 percent over a nine-month period only. This was a direct reflection of improvements in equipment availability, efficiency and product quality. A positive feedback regarding the smooth implementation of the scheme was also received from the responsible maintenance staff. Research limitations/implications The proposed scheme is intended mainly to the manufacturing industrial sector, which utilizes failure-prone equipment in running operations. Originality/value This study presents an original scheme that tries to avoid the many barriers of success frequently encountered during the implementation of TPM schemes, as reported in the literature. This scheme is unique in integrating between 5S and safety, health and environment initiatives, by capitalizing on the close relation between the two initiatives, and simplifying procedures for measuring how well the two initiatives are implemented in an organization in one score card. Different from previous studies, the scheme treats both “education and training” and 6S as a foundation to the core TPM principles.

Implementing total productive maintenance in a manufacturing small or medium-sized enterprise

“…The concept is later expanded to the maintenance and improvement of the production quality system, through the equipment, process and operator, and increases the commercial value of the product (Sharma & Singh, 2015;Parikh & Mahamuni, 2015). TPM implementation, which brings short and long-term improvements to the enterprise, including overall equipment efficiency (OEE) (Méndez & Rodríguez, 2017;Amorim, Hatakeyama & Rojas-Lema, 2018;Bataineh, Al-Hawari, Alshraideh & Dalalah, 2019). TPM minimizes the probability of equipment failure, manufacturing a non-conforming product and the occurrence of a safety accident (Patil & Raut, 2019).…”

Occupant Awareness towards the Application of Total Productive Maintenance in Green Office Building

“…Basically, TPM necessitates all individuals in the organisation from top management to floor staff be dedicated to the TPM programme (Bataineh et al, 2019). Generally, the philosophy of TPM embeds (Kanta Patra et al, 2005):…”

“…Typically, the application of TPM is more restrained in manufacturing industry (Weinstein et al, 2009, Bataineh et al, 2019. Nonetheless, its benefits are valuable to be practised in other industry, such as the construction industry (Andersson et al, 2015, Haddad, 2012, Jain et al, 2014, Kanta Patra et al, 2005.…”

“…It is obvious that both TPM and green building share the similar concept, which is maximising the equipment or building efficiency with optimised resources to increase the productivity of organisation (Hooi and Leong, 2017). In order to apply TPM in green building, involvement of all individuals in the organisation is compulsory, especially the employees (Bataineh et al, 2019). Under the philosophy of TPM, the employees must transform their mentality toward the scope of works and be able to initiate the operation and maintenance actions when necessary (Kanta Patra et al, 2005).…”

Analytical evaluation of TPM performance based on an economic criterion

“…Tsang et al (1999) suggested holistic approach to measure maintenance performance which should be linked to an organization's strategy in order to provide useful information for making effective decision and shaping desirable employee behaviour. Recently, Bataineh et al (2019) dealt with the same problem, by purposing a new TPM organization. In fact, in order to improve production effectiveness of equipment by facilitating the implementation of the key principles of TPM, the authors proposed 13 procedural steps, covering planning, implementation, checking, corrective action and control, in sequential TPM method.…”