Efficiency measurement based on novel performance measures in total productive maintenance (TPM) using a fuzzy integrated COPRAS and DEA method

Abstract

Total Productive Maintenance (TPM) has been widely recognized as a strategic tool and lean manufacturing practice for improving manufacturing performance and sustainability, and therefore it has been successfully implemented in many organizations. The evaluation of TPM efficiency can assist companies in improving their operations across a variety of dimensions. This paper aims to propose a comprehensive and systematic framework for the evaluation of TPM performance. The proposed total productive maintenance performance measurement system (TPM PMS) is divided into four phases (e.g., design, evaluate, implement, and review): i) the design of new performance measures, ii) the evaluation of the new performance measures, iii) the implementation of the new performance measures to evaluate TPM performance, and iv) the reviewing of the TPM PMS. In the design phase, different types of performance measures impacting TPM are defined and analyzed by decision-makers. In the evaluation phase, novel performance measures are evaluated using the Fuzzy COmplex Proportional Assessment (FCOPRAS) method. In the implementation phase, a modified fuzzy data envelopment analysis (FDEA) is used to determine efficient and inefficient TPM performance with novel performance measures. In the review phase, TPM performance is periodically monitored, and the proposed TPM PMS is reviewed for successful implementation of TPM. A real-world case study from an international manufacturing company operating in the automotive industry is presented to demonstrate the applicability of the proposed TPM PMS. The main findings from the real-world case study showed that the proposed TPM PMS allows measuring TPM performance with different indicators especially soft ones, e.g., human-related, and supports decision makers by comparing the TPM performances of production lines and so prioritizing the most important preventive/predictive decisions and actions according to production lines, especially the ineffective ones in TPM program implementation. Therefore, this system can be considered a powerful monitoring tool and reliable evidence to make the implementation process of TPM more efficient in the real-world production environment.

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“…Total Productive Maintenance (TPM) is a new maintenance strategy developed to meet new maintenance needs. TPM is an American style of productive maintenance that has been modified and improved to suit the Japanese industrial environment [17].TPM is a manufacturing initiative primarily formulated to enhance equipment efficiency throughout its lifespan through the active participation and motivation of the entire workforce and seeks to optimize the productivity of manufacturing equipment and is considered a Lean Management (LM) tool for improving performance and sustainability [18]. In conclusion, TPM focuses on maintaining and improving the integrity of production systems and quality through machines, equipment, and processes that add value to the product, avoiding breakdowns, delays, minor stoppages, and defects during the production process while providing a safe working environment and minor error [2,19].…”