Abstract
M.Phil. (Engineering Management)
Most manufacturing processes are not cost effective when it comes to operation and support,
this is due to low running capacities resulting in low productivity and elevated manufacturing
costs. One of the contributing factors to this unwanted outcome is ineffective maintenance
practices on the plant equipment. Maintenance practices play a vital role in ensuring that the
plant is available to produce, safe to work in, produces products of the right quality, and is cost
effective as costs associated with maintenance make-up a significant portion of the operating
budget of companies in the manufacturing sector.
A Variety of Process improvement tools exist, with each having a similar goal which is to
improve the performance of the business. Total Productive Maintenance is more than a
maintenance strategy, but a business improvement tool which companies can use to improve
customer satisfaction, reliability and remain competitive. TPM is implemented through basic
practices which are known as TPM elements or Pillars, and they are Housekeeping(5S),
Autonomous Maintenance(AM), Kaizen, Planned Maintenance, Training, Office TPM, Safety
Health and Environment. Companies from different parts of the world have been struggling for
sometime to evolve the best possible strategy for the successful implementation of TPM.
The purpose of this research is to help in understanding the impact of the TPM elements. This
also aids in understanding the role played by each of the TPM elements on the performance of
the facility as a whole. A South African manufacturing firm in the process of implementing
TPM is studied, to assess the progress made during the implementation process and the
learnings that come with it. Some TPM elements were practised in the manufacturing process
before the implementation began, meaning TPM was implemented previously.
Data is collected at the company being used as a case study before and after TPM
implementation. This data is used to calculate the availability, performance efficiency, quality
rate, and the overall equipment effectiveness (OEE). The OEE has improved since the
implementation with its value consistently above 80%. An improvement in the OEE indicates
the TPM pillars success in improving the business. For this happen the critical success factors
for effective implementation of TPM must be taken into account...