Abstract
Abstract:
Aim: Total Productive Management (TPM) is a strategic change management approach that has considerable impact on the internal efficiency of manufacturing organization, both in the developed countries and developing countries. It is an innovative maintenance program with a concept for maintaining plant and equipment by the involvement of all personnel based in an organization for continuous improvement of performance. The purpose of the research was to evaluate the impact TPM pillars have on equipment availability focusing on the planned maintenance pillar. The research objectives were to; determine how the planned maintenance pillar was used at the company under study and the extent to which it was applied; to determine the impact that TPM had on the company’s performance and finally to determine if the TPM pillars had helped in obtaining the overall expected results that rise from an effectively implemented TPM.
Methodology: A literature survey was undertaken into the elements and benefits of TPM, the pillars of TPM and finally the importance of equipment availability and overall equipment effectiveness (OEE). A quantitative and qualitative research approach was used in conducting the research. Structured interviews, questionnaires and company records were used in collecting data for the research. A total of 40 questionnaires were administered; 10 to the maintenance personnel and 30 to respondents from other departments of the company. Research data was analyzed using statistical package for social sciences (SPSS) and Microsoft excel.
Findings: The results from the research revealed the following, 42% of the respondents agreed a maintenance plan is prepared before any maintenance activity is carried out, 29% indicated a maintenance plan was not prepared before maintenance activities is carried out and the 29% indicated it was not prepared all the time. To determine whether planned maintenance was carried out according to schedule, 43% of the respondents indicated it was carried out according to schedule while 43% indicated planned maintenance are only carried out only when there is an equipment malfunction and 14% indicated planned maintenance actions are only carried out when need to perform maintenance arises. The researchers also the assessed how TPM had impacted on the company performance; 50% of the respondents believed TPM reduced equipment losses while 71% believed the system reduced equipment failures, 67% believed it improved productivity and 50% believed it reduced breakdown costs. As a result of implementing TPM strategy the company’s overall equipment effectiveness ranges from 51% to 55%.
Originality: The originality of the research steams from the fact that, the research has never been conducted before at the company under study and also the reeacrh focuses on the relevance of the TPM planned maintenace pillar on the company manufacturing performance.
Value: Firstly the value of this research was to inform management on the need to employ each TPM pillar with a degree of equal importance as the entire pillars play role in enabling a company achieve world class standards in terms of manufacturing performance and overall equipment effectiveness. Secondly it points out that practicing TPM strategies is one of the best practices to achieve world class manufacturing standards.