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Impact Analysis of Total Productive Maintenance: Critical Success Factors and Benefits José Roberto Díaz-Reza
Impact Analysis of Total Productive Maintenance: Critical Success Factors and Benefits José Roberto Díaz-Reza
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José Roberto Díaz-Reza
Jorge Luis García-Alcaraz
Valeria Martínez-Loya
Impact Analysis
of Total
Productive
Maintenance
Critical Success Factors and Benefits
Impact Analysis of Total Productive Maintenance
José Roberto Díaz-Reza Jorge Luis García-Alcaraz
•
Valeria Martínez-Loya
123
José Roberto Díaz-Reza Valeria Martínez-Loya
Universidad Autónoma de Ciudad Juárez Universidad Autónoma de Ciudad Juárez
Ciudad Juárez, Chihuahua, Mexico Ciudad Juárez, Chihuahua, Mexico
This Springer imprint is published by the registered company Springer Nature Switzerland AG
The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland
This work is dedicated, to my mother Socorro
Díaz, who since the first day has given me her
unconditional love and has always
encouraged me to be a better person.
To my aunt Gela for being another pillar
of the family.
To my brother (Demetrio), who has always
been an unconditional support.
To my sister-in-law Marisol, for being the one
who has always been a great support.
To my sisters (Laura and Juani) for
accompanying my mother, Aunt, and nephews
(Zaid, Yair, Iram, Yael and Sofia), who are
the joy of the family … Thank you very much
for everything that each one has contributed
to my life.
RP!
José Roberto Díaz-Reza
vii
viii Foreword
Part III has been called Research Problem, Objectives, and Methodology, where
the authors define the problems that exist in their environment regarding the TPM
implementation. Moreover, it is argued that there are many activities associated
with TPM where 75 have been identified, as well as benefits; however, there are no
studies that seek to relate them directly and indirectly, also there is no quantification
about the effect that these activities have on the benefits. Thus, the objective of this
book is to present through structural equation models, the relationships between
those activities that are required to implement TPM and the benefits that are
obtained. In addition, a series of sequential activities that the authors carry out in
order to fulfill this goal are defined, where the data gathered from the sector, its
validation, and the generation of the causal models can be mentioned.
Part IV is called Validation and Analysis of Data, where the authors already
applied the methodology to generate validity indexes from data obtained about the
industrial sector. Additionally, in this process, some of the activities and benefits are
deleted to improve those indexes, and as well as to generate stronger structural
equation models. Also, a descriptive analysis of the TPM tasks and benefits is
reported, where central tendency measures and dispersion are described, which
allows a discussion from a univariable perspective.
Finally, Part V is called Estructural Equation Models and it has been considered
that in this section, questions that researchers asked at the beginning of their book are
answered, because it is where the required tasks for TPM are completely related to the
benefits obtained. As a matter of fact, there are two types of structural equation
models: the simple ones, in which an activity is linked to a benefit, therefore they are
presented on purpose, since they are easy to understand, as the authors are introducing
more and more difficult models to the second ones that they call complexes, where
four variables already intervene. In addition, it is important to see how a sensitivity
analysis is performed for each complex to determine the probability of occurrence
from the variables when there are at their low and high values.
I hope that readers on this book will find the usage that is sought in it, since the
outcomes will allow identifying the main activities associated with the TPM
implementation and the benefits that are obtained. In addition, I know that many
readers may mention that relationships are sometimes logical and have common
sense, but a real contribution of this book is that it quantifies that relationship and
will make it easier for those interested to focus their attention on activities that are
crucial for their business in a specific way.
ix
x Preface
Technological status, Layout, and Warehouse management and the benefits are
divided into organizational, safety, and productivity. In addition, for each one
of these variables, efficiency indexes are obtained in order to know if the activities
and benefits actually contribute to its explanation.
Chapter 8 is titled Descriptive Analysis, which reports a series of indexes and
parameters associated with the characteristics of the sample and the data obtained.
In addition, 397 cases from the surveys applied to the maquila sector are reported,
as well as the sectors involved in the study, the gender, and years of experience
from the participants responding to the survey, as well as the position within it are
analyzed. Additionally, regarding activities and benefits, since they are estimated on
a Likert scale, the median is reported as a central tendency measure, and the
interquartile range as a measure of dispersion.
In Part V, which includes five chapters, the structural equation models are
described, where the activities required for TPM are related to the benefits; these
chapters are described below:
Chapter 9 is titled Simple Models, where three simple structural equation models
are reported, which integrate only one activity with a benefit from TPM, which are
duly justified. Similarly, a list of all the possible relationships that may exist
between the variables associated with the activities and the benefits is addressed,
but they are no longer fully explained, since only the dependent indexes are indi-
cated. In addition, in this chapter, the quantifications that determine the relationship
between the variables (activities and benefits) start to show up.
Chapter 10, which is titled Structural Equation Models: Human Factor—Part I,
presents two complex structural equation models, where the activities associated
with human factors are related to other activities, since it is assumed that there is
dependency between them. Also, a sensitivity analysis is reported at the end of each
model, which indicates the probabilities of occurrence for each of the variables
together and independently.
Chapter 11 is titled Structural Equation Models-Human Factor—Part II, which
presents two complex structural equation models, where the activities associated
with the human factor in the TPM implementation are already linked with the
benefits obtained from the tool. Also, the analyzes are interesting, since here the
first causal models appear, which allow managers to identify the activities where
they should focus their efforts on.
Chapter 12 is called Structural Equation Models-Technical Factors, as its name
indicates, it relates the technical factors associated with the activities required to
implement TPM with the benefits, and two complex models come out. In addition,
as in other models, the hypotheses are presented and justified with a literature
review; they are validated, and a conclusion is written from themselves.
Finally, Chap. 13 is titled Structural Equation Models—Methodological
Factors, which presents a complex structural equation model that integrates the
methodological factors and a second-order integrative model that coordinates all the
associated variables in a single model along with the activities and benefits, which
is incorporated by three latent variables. Also, this is the most significant model,
xii Preface
because it is the one allowing to observe from a general perspective the importance
that human resources have in the TPM implementation.
Authors hope that the content of this book will contribute to understand man-
agers and decision-makers in the TPM implementation, the relevance of this tool,
the appropriate management of the machinery and equipment available in their
production systems, and identify the tasks that are essential to acquire a specific
benefit focusing their efforts on it. In addition, we hope that enthusiast, academics,
and researchers can find this as a useful book for understanding the TPM in industry
with real applications.
The present project would not have been completed without the support of many
people who were directly and indirectly involved, and therefore, the authors want to
thank the following people and institutions:
• To all the maintenance managers and associated areas that answered our survey
to gather data from their industry, who commented on it, and allowed the access
to their companies.
• To all those students and coworker teachers who helped during the gathering
data process from the companies.
• To the National Council of Science and Technology (CONACYT), which
through the project called Thematic Network of Optimization Industrial
Processes has supported this project.
• To the Secretariat of Public Education of Mexico, who through the Program for
Professional Teacher Development (PRODEP) have supported this project.
• Special thanks to the Autonomous University of Ciudad Juárez (UACJ), our
work and study place, for their financial support during the book translation and
editing process.
• Also, our gratefulness to Alejandra Bautista, who is responsible for translating
the book, and her advice and patience has contributed to this project.
xiii
Contents
xv
xvi Contents
– Involve all employees from the senior management along with the machine
operators,
– Promote the PM through an organized management, that is, through a small
group of autonomous activities.
• TPM is not a maintenance program itself, it is a team management program that
combines and promotes the concepts of continuous improvement, and total
quality as well as the employees’ empowerment to achieve zero stoppages and
defects (Stephens 2004).
• TPM is a procedure to introduce maintenance considerations into the organi-
zation’s activities. It involves an operative and maintenance team that work
together to reduce waste, minimize downtimes, and improve the final product
quality (Eti et al. 2004).
• TPM is a methodology that aims to increase the availability/effectiveness of the
existing equipment in a certain situation, through the effort of minimizing entries
(improving and maintaining the equipment at an optimum level to reduce the
life cycle cost), and the investment in human resources that results in a better
hardware usage (Chan et al. 2005).
• TPM is a larger part of a Lean initiative, and its goal is generally to improve
uptime and equipment reliability (Press 2005).
• TPM is a philosophy that involves the entire organization, which increases the
knowledge levels, performance, efficiency, and teamwork in each area (Sun
et al. 2003).
• TPM is a maintenance program, which implies a recently defined concept for
plants and equipment maintenance; it can be considered as the “medical sci-
ence” for industrial machines (Mâinea et al. 2010).
• TPM represents a system for the effective technology process usage (Friedli
et al. 2010).
• TPM is a set of techniques to ensure that each machine in a production process
can always perform the required tasks (Anvari et al. 2014).
• TPM is a continuous improvement process focused on structured teams that
seeks to optimize production effectiveness by identifying and eliminating
equipment losses as well as production efficiency, throughout the production
system life cycle through the employees’ active participation at all levels of the
operational hierarchy (Attri et al. 2013a).
• TPM is a maintenance management approach focused on involving all the
employees of an organization in the equipment improvement. It consists of a
variety of methods, known for the maintenance management experience that are
effective in improving reliability, quality, and production (Das et al. 2014).
• TPM includes maintenance prevention, maintenance improvement, and pre-
ventive maintenance (Benjamin 1997; Filho and Utiyama 2016).
• TPM is the combination of preventive maintenance activities and the Total
Quality Management philosophy to create a TPM culture by providing
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trades, which began in the previous July.
February 4, 1898.
Re-election (by voting which began January 3) of
President Kruger for a fourth term of five years,
in the South African Republic.
February 18.
Death of Frances Elizabeth Willard, American social reformer.
March 6, 1898.
Death of Felice Cavalotti, Italian statesman and dramatist.
{709}
April 2, 1898.
Quashing of the sentence pronounced on M. Zola, upon his
appeal to the Court of Cassation.
Lease by China to Great Britain of the port of Wei-hai Wei
with adjacent territory.
April 7, 1898.
Death of Margaret Mather, American actress.
April 8, 1898.
Great victory of the Anglo-Egyptian army, under the Sirdar,
General Kitchener, over the Dervishes, on the Atbara.
May 1, 1898.
Destruction of the Spanish squadron in Manila Bay by the
American squadron under Commodore Dewey.
May 2, 1898.
Arrival of Aguinaldo at Hong Kong.
May 3, 1898.
Occupation of Cavite arsenal by American naval forces.
May 8, 1898.
General elections for a new Chamber of Deputies in France;
first balloting.
May 9, 1898.
Serious fighting in Milan, ending bread riots in that city
and elsewhere in northern Italy.
{710}
June 1, 1898.
Arrival of Admiral Sampson and his fleet off the entrance to
the harbor of Santiago de Cuba, to perfect the blockade of
the Spanish squadron.
Opening of the Trans-Mississippi Exposition at Omaha, Nebraska.
Enactment of law to provide for the arbitration of disputes
between employés and companies engaged in interstate commerce
in the United States.
June 2, 1898.
Death of George Eric Mackay, English poet.
June 3, 1898.
Sinking of the collier "Merrimac" in the channel of the
harbor-entrance at Santiago de Cuba, by Assistant Naval
Constructor Hobson. U. S. N.
June 6, 1898.
Bombardment of Spanish forts at Santiago de Cuba by the
American blockading fleet.
July, 1898.
Discussion and passage by the British Parliament of a
Local Government Act for Ireland.
July 1, 1898.
Assault by the American forces, at San Juan Hill and El Caney,
on the Spanish lines defending Santiago.
July 3, 1898.
Demand of General Shafter for the surrender of Santiago, under
the threat of bombardment; truce arranged by foreign consuls and
negotiations for surrender opened.
Destruction of the Spanish fleet of Admiral Cervera on its
attempting to escape from the blockaded port of Santiago de
Cuba.
July 4, 1898.
Opening of communications between General Anderson, commanding
the first expedition of the United States forces landed near
Manila, and General Aguinaldo, "commanding the Philippine
forces."
July 6, 1898.
Destruction of the Spanish cruiser" Alphonso XII.," when
attempting to escape from the harbor of Havana.
Adoption by the U. S. Senate of the joint resolution to
provide for the annexation of the Hawaiian Islands.
Exchange of Lieutenant Hobson and his fellow captives for
prisoners taken from the Spanish forces.
July 7, 1898.
Declaration of M. Cavaignac, Minister of War, in the Chamber
of Deputies, of his absolute certainty of the guilt of Captain
Dreyfus.
Death of Francisco Javier Cisneros, Cuban patriot.
Death of M. Buffet, French statesman.
{711}
August 3, 1898.
Urgent message from General Shafter to the United States War
Department, asking for the instant withdrawal of his forces
from Santiago, on account of the deadly ravages of yellow
fever, typhoid and dysentery.
August 4, 1898.
Orders given for the removal of the American army from
Santiago de Cuba to Montauk Point, Long Island.
August 7, 1898.
Acceptance by Spain of the terms of peace offered by the
United States.
Demand of Admiral Dewey and General Merritt for the
surrender of Manila.
Death of James Hall, American geologist.
August 8, 1898.
Death of Adolph Heinrich Joseph Sutro,
American mining engineer.
Death of Georg Moritz Ebers, German novelist and Egyptologist.
September 2, 1898.
Battle of Omdurman;
defeat of the Dervishes and occupation of the Khalifa's capital.
September 3, 1898.
Death of Wilford Woodruff, president of the Mormon Church.
September 4, 1898.
Resignation of M. Cavaignac from the French cabinet, because
of his opposition to a revision of the Dreyfus case.
September 6, 1898.
Enthronement of Queen Wilhelmina, at Amsterdam.
Turkish outbreak at Candia, Crete, against authority
exercised by the British admiral in the name of the
concerted Powers.
October, 1898.
Discovery of the Cape Nome mining region in Alaska.
Outbreak of Indians of the Leech Lake Reservation in
Northern Minnesota.
October 1, 1898.
Call by foreign representatives at Peking for guards of
marines to protect their legations.
Meeting of Spanish and American commissioners at Paris to
negotiate a Treaty of Peace.
October 5, 1898.
Demand of the Powers for the withdrawal of Turkish garrisons
from Crete.
October 6, 1898.
Decree by the Empress-Dowager of China commanding protection
to Christian missionaries and converts.
October 7, 1898.
Death of Blanche Willis Howard, Baroness von Teuffel,
American novelist.
Death of Abraham Oakey Hall, American lawyer and politician.
October 12.
Inauguration of General Julio Roca President of the
Argentine Republic.
Serious conflict at Virden, Illinois, growing out of a
strike of coal miners;
14 persons killed and 25 wounded.
Death of Reverend Calvin Fairbank, anti-slavery worker and
helper of the freedmen.
{712}
November 1, 1898.
Establishment of the Constitution of the United States of
Central America.
November 2, 1898.
Announcement by Lord Salisbury of the amicable settlement,
between France and Great Britain, of "the Fashoda incident."
November 5, 1898.
Death of David Ames Wells, American economist and publicist.
December 5, 1898.
Final raising of the "pacific blockade" of Crete by the Powers.
December 6, 1898.
General Guy V. Henry appointed Military Governor of Porto Rico.
1899.
January 1, 1899.
Formal relinquishment of the sovereignty of Spain over the
island of Cuba, by ceremonies performed at Havana.
January 4, 1899.
The Treaty of Peace between the United States and Spain sent
to the United States Senate by the President.
Proclamation of General Otis to the people of the Philippine
Islands, amending the instructions of the President.
January 5, 1899.
Proclamation of Aguinaldo to the people of the Philippine
Islands, counter to that of General Otis.
January 8, 1899.
Sensational resignation of the President of the civil section
of the French Court of Cassation.