Professional Documents
Culture Documents
Research Paper
Norlena bt Hasanan
Othman Yeob Abdullah,
Graduate School of Business
Univesity Utara Malaysia, Malaysia
norlena@uum.edu.my
ABSTRACT
Due to the necessities for strengthen the business strategic planning, the organization scrutinize
on optimizing the maintenance practices. Currently the maintenance practice is presently
deliberated as main elements and becoming increasingly difficult to ignore since the impact of
effective and efficient maintenance is important to increase the productivity and maximize the
effectiveness of the overall equipment effectiveness. Total Productive Maintenance (TPM) is a
systematic approach to understand the equipment’s function, the equipment’s relationship to the
product quality and the likely cause of failure of the critical equipment conditions. Introducing
TPM requires strategic planning and few studies had been made in the field of maintenance within
the context of power generation industry. Consequently, organization introduced TPM as a tool for
maintenance approach. TPM initiative commonly had been practice in manufacturing company
but nowadays others industries used this initiative as well. Aligned with that, power generation
industry started to embark on the TPM initiative to strengthen the power plant operation. This
paper discusses the state of TPM implementation in Malaysian power generation industry and
investigation of Critical Success Factors (CSFs) associated in implementing TPM. This paper
systematically investigates the TPM CSFs through questionnaire survey to the employees which
embarking the TPM in power station. The Statistical Package for Social Sciences (SPSS) software
version 21 was applied to perform the required statistical analysis of the data from surveys. As
results, the researcher found that the top management commitment, resource management,
training and work culture is the main elements of CSF due to high score in implementing TPM in
power generation industry. By identifying the TPM CSFs, the organization can improve and
supervise the TPM planning and activities during implementing the TPM in power generation
industry. Consequently, the successful of implementing TPM will support the organization business
performance towards the operational excellent.
Key Terms: Total Productive Maintenance (TPM), TPM in Industries, Power Generation Industry,
Critical Success Factors
In line with maintenance approaches, TPM well knowns as management system that
has the proven capacity when fully implemented to improve the business performance of a
production by the implementation of a safe, pleasant and productive workplace through the
optimization of people who work there and the equipment they rely on (Ahuja, 2009; Dogra,
Sharma, Sachdeva, & Dureja, 2011; McKone, & Weiss, 1998). Addition to that, the outcomes
of the TPM initiative are zero breakdown and zero defect to organization assets. Thus,
numerous scholar highlighted that to increase the availability of existing equipment and
reducing the need for further capital investment by implementing the TPM initiative (Mad
Lazim & Ramayah, 2010; Maggard, & Rhyne, 1992; McKone, & Weiss, 1998).
Nevertheless, the implementation of TPM initiative are depends on the environment factor,
organizational behavioral and organizational culture. The process of TPM implementation in
organization are obviously challenging and not all company could successfully complete the
TPM practice. Therefore, the organization must scrutinize the purpose of TPM
implementation before embarking on the TPM initiative in the organization. As mentioned
before, TPM are commonly implemented in various industries and mainly develop for
manufacturing industry. From the previous literature, Almeanaz (2010) study the TPM
implementation in steel industry while Haddad and Jaaron, (2012) has presented the research
on the TPM implementation in healthcare industry in Jordan. Thus, TPM has become highly
recognized as an approach on handling and managing the plant maintenance, plant
engineering, production improvement and product design ([Annamalai, 2011; Belassi &
Tukel, 1996). By looking at the positive impacts to the industry, TPM was implemented at
power generation by having the same goals. Realizing the system and process in power
generation industry is slightly different compare to other industries, there is need to study the
critical factors that contribute to the TPM initiative during the implementing phase.
To the date, the TPM concept is accepting and practicing from various industry.
People in industry believe the main goal of the TPM still the same which are guided on
managing assets and optimizing production (MY, 2012). Thus, many researchers carry out
the TPM topic in deep by looking at many subject such as TPM theoretical, TPM framework,
TPM pillars, TPM practicality and much areas. Mohammad Jafari, Lotfi, Felegari and
Hosseini (2014), from Iran studied the TPM implementation for steel industry meanwhile
Chetan, Shende, and Swapnil (2006), were carried out the case studied on TPM in the rolling
mill industry which is located in India. In Malaysia, Norddin, Zameri and Saman (2012), was
done the research in fertilizer process which implement TPM in plant industry and Badly
(2012) was carried out the TPM assessment in Malaysian Automotive SMEs. Therefore,
various study and research had been done and still continuing by the country in various sector
and industry. However, far too little attention has been paid to TPM implementation in the
utilities industry which focusing to the power generation company. The researcher believed,
utility industry is one of the key player contribute to the country growth and consequently
there is need to evaluate and validate the TPM implementation in power generation industry.
The coal power generations are composed with the boiler system, turbine system,
condensing and feed heating system, generator system and main transformer. The system of
the boiler purposely exchanges the coal combustion which is chemical energy into the
thermodynamic energy in the boiler through generating the steam from the boiler drum.
There are many boiler types such as a sub-critical boiler, boiler with reheater, single drum,
radiant and convectional of two-pass type superheaters, with controlled recirculation and
normal circulation. Wiser (2000) explained the Rankine cycle is the idealized cycle for steam
power plants, and could be describe as a heat engine process with a vapour power cycle. As
described by Kapooria, Kumar and Kasana (2008), the steam plant involves the process of
isentropic compression, isobaric heat supply, isentropic expansion and isobaric heat rejection.
The complexity of the process become the critical elements to the operators in ensuring the
equipment is operating in good condition. The equipment must operate with highly efficient
to produce high productivity and quality.
Realizing as main asset to the country, one of the IPPs located in Malaysia embarked
the TPM initiative. The organization start to embarked TPM initiative at the power station in
order to strategies the maintenance approach by maintaining the existing assets.
Consequently, TPM become a part of company strategy purposely to enhance strengthen the
power plant operation. The TPM steering community was initiated by the top management
purposely to drive the TPM program in station. Top management promptly promote the
TPM initiative to all levels of employees to ensure the TPM initiative deliver the objective
and goals. Since TPM launched in year 2010, the TPM program progressively implemented
among the operation staff which are responsible to operate the power plant. The TPM
program such as cleaning activities, identification of abnormalities, measuring the equipment
effectiveness, continuous improvement program, TPM competency and TPM assessment had
been done violently every year. After several years with multiple TPM program had been
instigated, the operation staff definitely adopt and practice the TPM initiative at the work
place. Furthermore, by looking at the positive impact to the organization, the researcher
believed there are restriction and critical issues facing by the origination during implement
the TPM initiative.
In order to ensure the initiative achieves the main goal, there are needs of measurable
element called Critical success factor (CSF). The CSFs described the factors that influence
the successful of the project, program, business, and activities with proper data analysis
Therefore, by looking at all the CSFs mentioned by the scholars, there are essential
things to carry out the CSFs assessment. CSFs indicate the willingness of various factors
which contribute to the successful of TPM initiative (Ahuja, & Khamba, 2008; Dogra,
Sharma, Sachdeva, & Dureja, 2011; Maggard, & Rhyne, 1992). The proactive action must be
taken to cater the weakness during TPM program to ensure the objective is achievable.
However, the different organization will have the different difficulties and restriction and
subject to the types of industry (Ahuja, & Khamba, 2008;). Hence, the researcher interest to
find out and analyzed the fissure in implementing TPM between industries. The main gap is
the TPM initiative basically implements at manufacturing industry but not at the process
industry.
"Critical success factors are those few things that must go well to ensure success for a
manager or an organization, and, therefore, they represent those managerial or enterprise
area, that must be given special and continual attention to bring about high performance.
CSFs include issues vital to an organization's current operating activities and to its future
success."
Nevertheless, due to little research piloted in this area of power generation industry,
the researcher has been conducted the through questionnaire to determine the TPM CSFs in
power generation industry. Based on the previous literature, there are four critical factors
could influence the successful of TPM implementation which gives significant impact to the
business performance in the context of power generation industry. The research hypothesis
was developed purposely to explain the correlation stated in the research objective which
consist of concepts. The research hypotheses purposely develop to carry out the empirical
testing which is explaining below:
Research Hypothesis 1: The top management roles and responsibilities on the TPM
activities not affect to the business performance.
Research Hypothesis 2: The resource management contribution for the TPM activities
not gives the significant impact to the business performance.
Research Hypothesis 4: The TPM work culture not affect to the business performance
power generation industry.
From the hypothesis, the theoretical framework had been developing accordingly.
Figure 3.1 shows the relationship of the critical factors in implementing the TPM to the
business performance.
Top management
Resource management
Business
Performance
Training and education
Work Culture
The Statistical Package for the Social Science (SPSS) software was applied to
perform required statistical analysis of the data from the distributed questionnaire. Before the
statistical analysis was conducted it was necessary to first evaluate the reliability and validity
of the instruments to ensure that the finding would be reliable and valid. The management of
the company, the TPM facilitator, TPM expert, and TPM community was validate the
questionnaire before distributed to the respondent.
From the survey exercise, 100 respondents out of 150 employees in operation
department response to the survey questionnaire. This response rate is 66.7% and it is mainly
being completed by the employees involves in the TPM activities at the workplace.
According to Sekaran (2003) respondents to the survey questionnaire is enough if the sample
size is from 30 to 500 respondents and is sufficient to review and depends on the population
of the selective research area.
In the beginning, the normality test was carried out for this study purposely to ensure
there are no extreme scores on an individual variable, or on a set of variables, that they will
distort the overall results. In addition, the normality test deliberately to examine the data
distribution and to identify the likely data pattern distribution. Therefore, the researcher
carries out normality test descriptive analysis for each dimension. Before analysis the
dimension, the researcher came out with summary analysis for the normality test presented in
The mean for management result is 3.66 which indicate that normality of mean with
the standard error is 0.8554. The probability distribution skewness is -1.164 and it means the
distribution is skewed to the left. Besides that, it can be explained the mean of the construct is
less than mode. Kurtosis value for management is 2.176 and it means the distribution
produces fewer and less extreme outliers than does the normal distribution. For continuous
improvement construct, the skweness value is -1.357 which means the distribution curve is
skewed to the left. Due to that, the mean is usually less than the median and the few low
scores tend to shift the mean to the left. The mean for continuous improvement is 3.658 and
the kurtosis value is 2.817. The kurtosis value is close to 3 which is normal distribution for
univariate. The skewness for training is -1.037 which is at negative value and its mean the
distribution skewed to the left with the standard error value is 0.241. The kurtosis value is
2.817 and close to 3 which is normal distribution for univariate. The skewness for resource
management is -1.118 negative and its mean the distribution skewed to the left with the
standard error value is 0.241. The kurtosis value is 2.310 and close to 3 which is normal
distribution for univariate. The mean for work culture normality test is 3.5833 and the
skewness for work culture is -0.846 negative and its mean the distribution skewed to the left
with the standard error value is 0.241. The skewness value is less than -1.0 and can
acceptable because it close to 0. Its means the respondent realized that the culture could be
one of the factor influence the TPM activities. The kurtosis value is 1.276 which is quit far
from the normal distribution which is at 3.0 values. Besides, the descriptive normality test for
general question asked to the respondent also presented in the normality test. The kurtosis
value is 3.589 and the skewness value is -1.453 where the distribution is skewed to negative
distribution. The kurtosis reading is closed to 3.0 which is normal distribution peak.
The researcher carried out the KMO and Bartlett’s Test of Sphericity in order to
measure of sampling adequacy which indicates the variable ratio for the analysis being
conducted. In most academic and business studies, KMO & Bartlett’s test plays an important
role for accepting the sample adequacy. Table 4.2 shows the KMO and Bartlett’s Test for this
research. For this research, the KMO of Sampling Adequacy is 0.919 and within the
acceptable range. Besides, the Bartlett’s test of sphericity results is 0 which mean the result is
more than 0.005. Its mean the data significantly meaningful to carried out the further analysis
for this research.
Nevertheless, the researcher carried out Cronbach's alpha analysis. Cronbach's alpha
is a measure of internal consistency, that is, how closely related a set of items are as a group.
It is considered to be a measure of scale reliability. A "high" value for alpha does not imply
that the measure is unidimensional. If, in addition to measuring internal consistency, you
wish to provide evidence that the scale in question is unidimensional, additional analyses can
be performed. Due to that reason, the reliability test, the researcher carried out Cronbach
Alpha test for all the constructive. Table 3 showed the analytical result test for Cronbach
alpha α for all dimensions.
Table 4: Cronbach Alpha results
Dimension Cronbach Alpha No of item
The result for Hypothesis 1 Top management shows Cronbach alpha α is more than
0.9 with the value is 0.945 at the excellent value. The high value for Cronbach alpha
represents the reliability of the scores. The Hypothesis 2 on the resource management
presents Cronbach alpha α value is more than 0.9 at 0.961 at the excellent value. The high
value for Cronbach alpha represents the reliability of the scores. Hypothesis 3 regarding the
training shows Cronbach alpha α is more than 0.9 with the value is 0.924 at the excellent
range. The high value for Cronbach alpha represents the reliability of the scores. For the
construct, work culture which is the Hypothesis 4 shows Cronbach Alpha α is more than 0.9
with the value is 0.934 at the excellent range also. In addition, the high value for Cronbach
alpha represents the reliability of the scores for the dimension. In addition, the researcher
carries out the Cronbach Alpha test for independence variables. Result shows the Cronbach
alpha α is more than 0.9 with the value is 0.959 at the excellent range which mean high
reliability and high consistency of the measurements.
The researcher found that the proposed model is a good descriptor of the relationship
between the dependent and predictor variables. This is because given the R-square value of
0.823 implies that the four predictor variables explain about 82.3% of the variance in the
CSFs. Therefore, it is a quite good and respectable result. Table 4.5 show the model summary
for multiple regressions which is represents the R-square and df.
Table 6: Model summary for multiple regressions
The ANOVA table below shows that the F value is 110. The ANOVA Table 6 shows
p is 0.00, df is 4 and F value is 110.264. Due to that, the decision is to reject the null
hypothesis and support the alternate hypothesis. The researcher develops the model from the
multiple regressions then.
Table 7: ANOVA for multiple regression
Based on the coefficients results showed in Table 8, the intercept constant value for
the multiple regression model is 0.272, constant value for management is 0.527, constant
value for training is 0.417, constant value for work culture is -0.016 and constant value for
resources is 0.018.
Table 8: Multiple regression coefficient
The researcher comes out with distribution plot thru the equation and prediction from
the model. As presented below, the dependent variable is continuous improvement as
constant variables. The prediction is coming from the 4 IVs which consist with management,
training, work culture and resources.
During the data analysis, the study also carried out the T-test to find the significant
different between 2 groups which are executive and non-executive. The t-test tells us if the
variation between two groups is significant between executive and non-executive. In deep,
purposely the comparison is involving the different level of job descriptions, task and level of
educations. The table 10 shows the group statistic between executive and non-executive.
Table 10: Group statistic for Independent test
Ratio between both groups is 90:10 which are presented 90% of the respondent from
non-executive and 10% of the respondent is coming from executive. In general, the results
In total by looking at the Levene,s test for equality of variances, the p value for all
dimensions is bigger than alpha value 0.05 except foe management dimension. Therefore, the
researcher accepts the null hypothesis and rejects the alternate hypothesis. It can have
concluded that there is no significant level of dimension for, continuous improvement,
training, resources, and work culture for executive and non-executive. Besides, by looking at
the t-test equality for means column, the p value for all dimensions is bigger than alpha value
0.05. Therefore, the researcher accepts the null hypothesis and rejects the alternate
hypothesis. It can be concluded that there is no significant level of dimension for
management, continuous improvement, training, resources, and work culture for executive
and non-executive.
5. CONCLUSION
This study deliberated the theory development on the critical success factors on
implementing TPM in power generation industry in order to increase the business
performance. There is much research that highlighted that the need of Top Management
commitment in ensuring successful of TPM implementation in various industries. Therefore,
the researcher believed the Top Management is the key factors on driving and organizing the
TPM initiative. Besides that, the researcher interest to examine the Top Management
capabilities on energizing the new initiative. In fact, there is important on realizing the top
REFERENCES
Abdullah, F. (2003). Lean manufacturing tools and techniques in the process industry with a focus on
steel (Doctoral dissertation, University of Pittsburgh)
Abdullah, F., & Rajgopal, J. (2003, January). Lean manufacturing in the process industry. In IIE
Annual Conference. Proceedings (p. 1). Institute of Industrial Engineers-Publisher.
Abdulmalek, F. A., Rajgopal, J., & Needy, K. L. (2006). A classification scheme for the process
industry to guide the implementation of lean. Engineering Management Journal, 18(2), 15-25.
Ahuja, I. P. S., & Khamba, J. S. (2008a). Assessment of contributions of successful TPM initiatives
towards competitive manufacturing. Journal of Quality in Maintenance Engineering, 14(4),
356-374.
Ahuja, I.P.S. and Khamba, J.S., (2008c). Strategies and success factors for overcoming challenges in
TPM implementation in Indian manufacturing industry. Journal of Quality in Maintenance
Engineering, 14(2), pp.123-147.
Ahuja, I. S., Khamba, J. S., & Choudhary, R. (2006), January). Improved organizational behavior
through strategic total productive maintenance implementation. In ASME 2006 International
Mechanical Engineering Congress and Exposition (pp. 91-98). American Society of
Mechanical Engineers.
Belassi, W. and Tukel, O.I., 1996. A new framework for determining critical success/failure factors in
projects. International journal of project management, 14(3), pp.141-151.
Becker, J. E. (2001). Implementing 5S: To promote safety & housekeeping. Professional Safety,
46(8), 29.
Brah, S. A., & Chong, W. K. (2004). Relationship between total productive maintenance and
performance. International Journal of Production Research,42(12), 2383-2401.
Chan, F. T. S., Lau, H. C. W., Ip, R. W. L., Chan, H. K., & Kong, S. (2005). Implementation of total
productive maintenance: A case study. International Journal of Production Economics, 95(1),
71-94.
Chen, T. L. (2009). Real-time turbine maintenance system. Expert Systems with Applications, 36(4),
8676-8681.
Cigolini, R., & Turco, F. (1997). Total productive maintenance practices: a survey in Italy. Journal of
Quality in Maintenance Engineering, 3(4), 259-272.
Dogra, M., Sharma, V. S., Sachdeva, A., & Dureja, J. S. (2011). TPM–a key strategy for productivity
improvement in process industry. Journal of Engineering Science and Technology, 6(1), 1-16.
Freund, Y.P., 1988. Critical success factors. Planning Review, 16(4), pp.20-23.
Graisa, M., & Al-Habaibeh, A. (2011). An investigation into current production challenges facing the
Libyan cement industry and the need for innovative total productive maintenance (TPM)
strategy. Journal of Manufacturing Technology Management, 22(4), 541-558.
Kumar, P., Varambally, K. V. M., & Rodrigues, L. L. (2012). A Methodology for Implementing Total
Productive Maintenance in Manufacturing Industries–A Case Study. International Journal of
Engineering Research and Development, 5(2), 32-39.
Mad Lazim, H., & Ramayah, T. (2010). Maintenance strategy in Malaysian manufacturing
companies: a total productive maintenance (TPM) approach.Business Strategy Series, 11(6),
387-396.
Maggard, B. N., & Rhyne, D. M. (1992). Total productive maintenance: a timely integration of
production and maintenance. Production and Inventory Management Journal, 33(4), 6.
McKone, K. E., & Weiss, E. N. (1998). TPM: planned and autonomous maintenance: bridging the gap
between practice and research. Production and Operations Management, 7(4), 335-351.
MY, B.S., 2012. Total productive maintenance: a study of Malaysian automotive SMEs.
In Proceedings of the World Congress on Engineering (Vol. 3).
Patterson, J. W., Fredendall, L. D., Kennedy, W. J., & McGee, A. (1996). Adapting total productive
maintenance to Asten, Inc. Production and Inventory Management Journal, 37(4), 32.
Patterson, J. W., Kennedy, W. J., & Fredendall, L. D. (1995). Total productive maintenance is not for
this company. Production and Inventory Management Journal, 36(2), 61.
Pool, A., Wijngaard, J., & Van der Zee, D. J. (2011). Lean planning in the semi-process industry, a
case study. International Journal of Production Economics, 131(1), 194-203.
Schuman, C. A., & Brent, A. C. (2005). Asset life cycle management: towards improving physical
asset performance in the process industry. International Journal of Operations & Production
Management, 25(6), 566-579.
Seng, O. Y., Jantan, M., & Ramayah, T. (2005). Implementing total productive maintenance (TPM) in
Malaysian manufacturing organization: an operational strategy study. The ICFAI Journal of
Operations Management,4(2), 53-62.
Söderholm, P., Holmgren, M., & Klefsjö, B. (2007). A process view of maintenance and its
stakeholders. Journal of Quality in Maintenance Engineering, 13(1), 19-32.
Starr, A., & Ball, A. (2000). Systems integration in maintenance engineering. Proceedings of the
Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
214(2), 79-85.
Swanson, L. (1997). An empirical study of the relationship between production technology and
maintenance management. International Journal of Production Economics, 53(2), 191-207.
Turbide, D. A. (1995). Japan's new advantage: total productive maintenance.Quality Progress, 28(3),
121.
Waeyenbergh, G., & Pintelon, L. (2002). A framework for maintenance concept development.
International journal of production economics, 77(3), 299-313.
Willmott, P., & McCarthy, D. (2000). TPM-A Route to World Class Performance: A Route to World
Class Performance. Newnes.