Study of success factors of TPM implementation in Indian industry towards operational excellence: An overview

Abstract

Presently the manufactures are facing a great pressure to reduce cost of manufacturing and provide new and quality products in the market on a regular basis. The India's manufacturing sector is striving hard towards operational excellence. Reduction of waste, improvement of quality, higher through put and overall more efficient production system is leading India towards a manufacturing revolution. A good number of companies have started implementing a range of business strategies including going lean, and using manufacturing strategies such as TPM, TQM, Six Sigma, JIT etc. to obtain operational excellence. Total Productive Maintenance (TPM) refers to a management system for optimizing the productivity of manufacturing equipment. A study to evaluate the implementation aspects and success factors of TPM initiatives taken by Indian industry for achieving manufacturing excellence is carried out and presented in this paper. There remained considerable improvement in the morale of employees, skill level of employees, technological up-gradation, machine conditions, and customer satisfaction level after TPM. Also the industries remained successful in improving their overall equipment effectiveness (OEE) up to 30% and some of them achieved the world class level of 95% OEE.

Difficulties observed when implementing Total Productive Maintenance (TPM): empirical evidences from the manufacturing sector

“…Collaborators' resistance related to cultural changes provided by the implementation of TPM. (Ahuja & Khamba, 2008b;Aspinwall & Elgharib, 2013;Attri, Grover, Dev, & Kumar, 2013;Bamber, Sharp, & Hides, 1999;Bartz et al, 2012;Carrijo, 2008;Cigolini & Turco, 1997;Cooke, 2000;da Costa et al, 2015;Estanqueiro & Lima, 2006;Gupta, Vardhan, & Al Haque, 2015;Lawrence, 1999;Milara Guedes, 2009;Poduval, Pramod, & Jagathy Raj, 2015;Rodrigues & Hatakeyama, 2006) 3…”

“…Collaborators' deficit understanding the philosophy, principles and tools that compose the TPM program. (Ahuja & Khamba, 2008b;Aspinwall & Elgharib, 2013;Attri et al, 2014Attri et al, , 2013Baglee & Knowles, 2010;Bamber et al, 1999;Carrijo, 2008;da Costa et al, 2015;Gupta et al, 2015;Lawrence, 1999;Milara Guedes, 2009; P.S. Poduval et al, 2015;Rodrigues & Hatakeyama, 2006;Singh et al, 2016) 6…”

“…Lack of support by senior management to raise awareness on the importance of the program. (Ahuja & Khamba, 2008b;Ahuja & Kumar, 2009;Aspinwall & Elgharib, 2013;Attri et al, 2014Attri et al, , 2013Bamber et al, 1999;Carrijo, 2008;Cooke, 2000;Gupta et al, 2015;Kelly, 2006;P.S. Poduval et al, 2015;Poduval et al, 2013;Singh et al, 2016) 8…”

“…Poor planning related to targets and goals to be achieved by deploying the TPM program. (Ahuja & Khamba, 2008b;Aspinwall & Elgharib, 2013;Attri et al, 2014;Bamber et al, 1999;Estanqueiro & Lima, 2006;Graisa & Al-Habaibeh, 2011;Gupta et al, 2015;Milara Guedes, 2009;Poduval et al, 2015;Singh et al, 2016) 11 Non-compliance with all initially planned sequential stages. (Aspinwall & Elgharib, 2013;Attri et al, 2014;Bamber et al, 1999;Estanqueiro & Lima, 2006;Milara Guedes, 2009;Rodrigues & Hatakeyama, 2006;Singh et al, 2016;Torres, 2014) Lack of a common language to be used by all employees in the implementation of the program's activities.…”

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

“…Similarly, Ma et al [36] reported that TPM increases production system efficiency, brings social benefits, and promotes management systems in production departments. On the other hand, Gupta, Vardhan, and Haque [13] mention that TPM increases employee morale and skills, improves the use of technology, and enhances equipment working conditions and customer satisfaction. Additionally, successful industries that implement TPM increase their overall equipment efficiency (OEE) by 30%, and some have increased OEE by 95%.…”