Literature Review of Implementation of Total

Productive Maintenance in Manufacturing Area

Muhammad Shoaib
MSIEM18F18

Background
Equipment management has gone
through many phases
 Breakdown maintenance
 Preventive maintenance
 Predictive maintenance
 Corrective maintenance
 Total productive maintenance
Breakdown maintenance
 Maintenance strategy, where repair is done after the equipment failure
Preventive maintenance
 Physical check up of the equipment to prevent equipment breakdown
and prolong equipment service life. PM comprises of maintenance
activities that are undertaken after a specified period of time or
amount of machine use
Predictive maintenance
 Maintenance is initiated in response to a specific equipment condition
or performance deterioration, diagnostic techniques are deployed to
measure the physical condition of the equipment such as temperature,
noise, vibration, lubrication and corrosion
Corrective maintenance
 Concept is to prevent equipment failures is further expanded that the
equipment failure can be eliminated (improving the reliability) and the
equipment can be easily maintained, difference between corrective
and preventive maintenance is that a problem must exist before
corrective actions are taken
 Total Productive Maintenance
Total Productive Maintenance is an innovative approach to maintenance that optimizes equipment effectiveness,
eliminates breakdowns and promotes autonomous maintenance by operators through day-to-day activities
involving total workforce. The Japanese develop the concept of TPM based on Preventive Maintenance concepts
and methodology. This concept was first introduced by Nippon Denso Co. Ltd of Japan, a supplier of Toyota Motor
Company, Japan in 1971 (Nakajima, 1989).
Article Details (Authors, Years, Methodology / Approach / Respondents / Key Findings
Title) Analysis

(Geometry & Analysis, 2011)
TOTAL PRODUCTIVE MAINTENANCE
IN MANUFACTURING INDUSTRY
• Applied math tools
• correlation between TPM components
stress and producing performance
dimension
• SPC control charts
• OPL (one point lessons)
• Planned maintenance management,
focused improvement, autonomous
maintenance and education and
training have significant
contribution towards manufacturing
performance such as lower cost,
higher quality, strong delivery and
increased productivity

(Shen, 2015) •  Total productive maintenance & its  TPM has been widely known in
pillars manufacturing environment, this proactive
maintenance strategy contributed to
• 5S System manufacturing performance improvements
Total Productive Maintenance: A Case OEE=Availability (A) ×Performance efficiency
Study in Manufacturing (P) ×Rate of quality like top management leadership and
Industry involvement, traditional maintenance
practices and holistic TPM implementation
initiatives, performance in organization
increases through proactive TPM initiatives.
Article Details (Authors, Years, Methodology / Approach / Respondents /
Title) Analysis
(Kumar Sharma & Gopal Sharma, 2014) • Pareto Chart
• Box plots
• FMEA as well as control charts
Integrating Six Sigma Culture and TPM
Framework to Improve Manufacturing
Performance in SMEs
(Rajput & Jayaswal, 2012) • Kaizan
• Autonomous Maintenance
• Focused Improvement
A Total Productive Maintenance (TPM) • Planned Maintenance.
Approach To Improve Overall • Quality Maintenance
Equipment Efficiency • Office TPM
Key Findings
• This paper shows for successful
implementation of operator
involvement should be increased as
well ownership of process through
autonomous maintenance paradigm
•  Good maintenance is prime to
productive producing environment.
Total Productive Maintenance (TPM) is
an alternate approach to
instrumentation maintenance that
seeks to realize zero breakdowns & zero
defects
• On average 21% cost will be saved if
maintenance information are
monitored
Article Details (Authors, Years,
Title)
(Sharma, Kumar, & Kumar, 2006)
Manufacturing excellence through
TPM implementation: a practical
analysis
(R.K & G.R., 2016)
Optimization of Overall Equipment
Effectiveness Through Total
Productive Maintenance Perspective •
– A Case Study
Methodology / Approach / Respondents / Key Findings
Analysis
• Kaizen • After implementation of TPM program.
• FMEA The availability of cell improved by 17
• PDCA cycle percent, performance efficiency by 8
percent and quality rate by almost 20
percent. The OEE measure had increased
from 39 to 69 percent
• OEE • The findings indicate that TPM not only
• 5 Why Analysis leads to increase in efficiency and
effectiveness of manufacturing systems,
• Fishbone diagram measured in terms of OEE index, by
Autonomous Maintenance reducing the wastages but also prepares
the plant to meet the challenges, detailed
analysis and suggestions the OEE of CNC
lathe machine improves from 31.21% to
74.47%
Article Details (Authors, Years, Methodology / Approach / Respondents / Key Findings
Title) Analysis

(Batumalay & Santhapparaj, 2009)
Overall Equipment Effectiveness
(OEE) through Total Productive
Maintenance (TPM) Practices – A
Study across the Malaysian Industries •
• Planned Maintenance (PM)
• Quality Maintenance (QM)
• Training and Education and the Overall
Equipment Efficiency (OEE)
SPSS
• Results shows maintenance
department engage 67.6%
breakdown maintenance, 24.3%
preventive maintenance & 8.1% not
applicable. Equipment down-time
was a significant reason for plant
under usage with 52% brought
about by deficiency of extras, 32%
deficiency of raw materials, 8%
because of power issue

(Friedli, Goetzfried, & Basu, 2010) • TPM • Management commitment and company
a. Preventive maintenance culture
Analysis of the Implementation of • Employee involvement and continuous
Total Productive Maintenance, Total •
TQM improvement
Quality Management, and Just-In- a. Process management • Functional integration and qualification
Time in Pharmaceutical b. Customer integration
Manufacturing c. Supplier quality management
• JIT
a. Set up time reduction
b. Layout optimization
Article Details (Authors, Years,
Title)
(Binti Aminuddin, Garza-Reyes, Kumar,
Antony, & Rocha-Lona, 2016)
An analysis of managerial factors
affecting the implementation and use of
overall equipment effectiveness
(Department of Electrical Power •  Total Productive Maintenance
Engineering and Mechatronics Chair of •
Mechatronics Implementation of Total
Productive Maintenance ( TPM ) in a
machine shop Kogu tootmistegevuse
hoolduse meetodi rakendamine
masinatöökojas, 2017)
Implementation of Total Productive
Maintenance (TPM) in a machine shop
Methodology / Approach / Respondents /
Analysis
• Overall equipment effectiveness
(OEE)
• 5 hypotheses and 4 analysis queries
were developed and tested
employing set of descripitive
statistics
• Chi-square and analysis of variance
•  TPM could be a set up that
Overall Equipment effectiveness
Key Findings
• Overall equipment effectiveness
(OEE) is source of foundation of
these two business improvement
strategies as it tackles the
underlying losses that impede
equipment efficiency 
concentrates on total involvement of
entire force to implement a
comprehensive maintenance program
for all instrumentation or machines
throughout their life
Article Details (Authors, Years,
Title)
(Hama Kareem & Hama Amin, 2017)
Ethical and Psychological Factors in 5S
and Total Productive Maintenance
(Sharma, Maheshwari, Juneja, &
Rajput, 2017)
Design of a total productive
maintenance model for effective
implementation: Case study of a
chemical manufacturing company
Methodology / Approach / Respondents / Key Findings
Analysis
• Survey & Questionaire • The findings of this paper revealed
that ethical factors had a larger role
than psychological factors in the
implementation. Thus, based on the
findings, organisations are
recommended to provide financial
and moral support to employees to
enable a comprehensive
implementation of 5S and TPM
aimed at obtaining the desired
results
• Research design and approach • The main focus is on how to improve
visibility of wastes in process and
• Data collection
a. Interviews quantifying them. OEE is guided by the
head of the executives through
b. Direct Observations powerful estimation and expanding
c. Questionnaires process effectiveness intensive disposal
of all misfortunes. OEE offers a method
for controlling the entire generation
process by examining results from the
totality of occasions. Production
backlogs and breakdowns are always
blame on machine failure.
Article Details (Authors, Years, Methodology / Approach / Respondents / Key Findings
Title) Analysis

(OMOREGBE & TAIWO, 2017) • Structured questionnaires using • The result shows a weak positive
descriptive and inferential statistics relationship between reactive
PRODUCTION FACILITIES maintenance as well competitive
MAINTENANCE PRACTICES AND advantage of corporations
SUSTAINABLE COMPETITIVE preventive maintenance
ADVANTAGE IN THE PAINT
MANUFACTURING INDUSTRY,

(Jaiswal, Sane, & Karandikar, 2016) • Researcher opted for Work Study •  Effective designing & instrumentation
techniques which are Method Study and for production processes will promote
Work Measurement optimum productivity
Improving Productivity in a Paint
Industry using Industrial Engineering
Tools and Techniques
Article Details (Authors, Years,
Title)
(Kenné & Boukas, 2003)
Hierarchical control of production and
maintenance rates in manufacturing
system
(Ahuja & Khamba, 2008)
Total productive maintenance:
literature review and directions
Methodology / Approach / Respondents / Key Findings
Analysis
• Heuristical Method • to evaluate current maintenance
• Singular perturbation approach system, to determine overall
equipment effectiveness w.r.t. key
performance indicators with success
factors of TPM. Results shows
maintenance department engage
67.6% breakdown maintenance,
24.3% preventive maintenance &
8.1% not applicable.
• 5S The paper reveals the important issues in
• OEE Total Productive Maintenance ranging from
maintenance techniques, framework of
TPM, overall equipment effectiveness (OEE),
barriers and success factors in TPM
implementation.
Article Details (Authors, Years,
Title)
(Yamashina, 1995)
Japanese manufacturing strategy and •
the role of total productive
maintenance
(Attri, Grover, Dev, & Kumar, 2013)
Analysis of barriers of total
productive maintenance (TPM)
Methodology / Approach / Respondents /
Analysis
• Just-in-time product developments
Cost reduction with the help of TPM
• 5S
• Questionnaire based survey
• ISM (Interpretive structural modelling)
approach
Key Findings
• one is attractive products and the other is
strong manufacturing capability. No
matter how well equipment was
designed, it is liable to have design
weaknesses and will deteriorate as time
passes. To make matters worse, it needs
alteration and adjustment to cope with
increasing change of market demand
• Lack of top management commitment
and support
• Lack of training and education
• Lack of motivation
• Employee resistance
• Poor relation between production and
maintenance department
Article Details (Authors, Years,
Title)
(Kam Loi, 2001)
Total Productive Maintenance and
effectiveness of Occupational Health
and Safety Management Systems
(Benjamin, Marathamuthu, &
Murugaiah, 2015)
The use of 5-WHYs technique to
eliminate OEE’s speed loss in a
manufacturing firm
Methodology / Approach / Respondents / Key Findings
Analysis
• Questionnaires • An effective and proactive safety culture
• T-test method is essential to improve safety
• After a certain point technology cannot
achieve further improvement in safety,
rather, organizational and cultural factors
may be important - yet these have not
been widely explored
• lean manufacturing • 5-whys analysis technique in a
• 5-whys analysis manufacturing industry completely
• TPM eliminated its top speed loss and resulted
• Speed loss in a valuable savings of USD 32,811.5 per
year
the 5-whys technique is a key tool to reduce
waste in a lean manufacturing environment
Article Details (Authors, Years, Methodology / Approach / Respondents / Key Findings
Title) Analysis

(Duffuaa & Ben-Daya, 1995) SPC tools • Attention has shifted from the economy
Improving maintenance quality using •
Histogram of scale to the economy of scope. Today’s
SPC tools • Cause and effect (fishbone) diagram. market conditions are characterized by
• Pareto analysis (diagram) more emphasis on variety, delivery
• Control charts performance and quality. Product life
• Scatter diagram cycles are shrinking.
• Checklist

(Okhovat, Khairol, Mohd, & Nehzati,

2012)

Development of world class

manufacturing framework by using
six-sigma, total productive
maintenance and lean
Gap Analysis

 Process and product quality are a key part of every person’s performance.
 Equipment failures and off-quality product can and will be prevented.
 If it ain’t broke, fix it anyway.
 Equipment performance can be managed by monitoring
 The findings reveals ethical factors have greater impact than psychological factor in its
implementation. So organizations are prescribed to give budgetary and good help to
representatives to empower a thorough execution of 5S and TPM planned for getting
the ideal outcome
Thank You