Strategies and success factors for overcoming challenges in TPM implementation in Indian manufacturing industry

Purpose – The purpose of this study is to evaluate the challenges before Indian manufacturing organizations for adapting to proactive total productive maintenance (TPM) initiatives. The aim of this research is to critically examine the factors influencing the implementation of TPM practices in the Indian manufacturing industry, and to devise an overall maintenance strategy for overcoming obstacles to successful TPM implementation.Design/methodology/approach – The study focuses on systematic identification of obstacles in TPM implementation and working out success factors towards improving manufacturing performance in Indian industry through strategic TPM initiatives.Findings – The study highlights the strong potential of TPM implementation initiatives in affecting organizational performance improvements. The paper reveals that implementing TPM is by no means an easy task, which is heavily burdened by organizational, cultural, behavioral, technological, operational, financial, and departmental barriers.Res...

[1]  Michael L. George,et al.  Lean Six Sigma : combining Six Sigma quality with lean speed , 2002 .

[2]  Barrie Dale,et al.  A study of total productive maintenance implementation , 2001 .

[3]  Wendy L. Currie,et al.  Managing AMI in a Just‐In‐Time Environment in the UK and Japan , 1992 .

[4]  Inderpreet Singh Ahuja,et al.  Improved Organizational Behavior Through Strategic Total Productive Maintenance Implementation , 2006 .

[5]  Ashraf Labib.  A framework for benchmarking appropriate productive maintenance , 1999 .

[6]  A. Ollila,et al.  Maintenance has a role in quality , 1999 .

[7]  J. Wayne Patterson,et al.  Maintenance: Modeling Its Strategic Impact , 1997 .

[8]  Jatinder N. D. Gupta,et al.  Managing supply chains for competitiveness: the Indian scenario , 2006 .

[9]  Jonas Hansson,et al.  Managing commitment: increasing the odds for successful implementation of TQM, TPM or RCM , 2003 .

[10]  John J. Lawrence.  Use mathematical modeling to give your TPM implementation effort an extra boost , 1999 .

[11]  Miguel Martinez Lucio,et al.  Fads, Techniques and Control: The Competing Agendas of TPM and TECEX at the Royal Mail (UK) , 2000 .

[12]  James F. Cox,et al.  A study of JIT implementation and operating problems , 1988 .

[13]  B. N. Maggard,et al.  Total productive maintenance; TPM that works , 1989, Proceedings. Seventh IEEE/CHMT International Electronic Manufacturing Technology Symposium,.

[14]  C. Madu.  Competing through maintenance strategies , 2000 .

[15]  C. Vamvalis,et al.  TPM implementation in Land‐Rover with the assistance of a CMMS , 1995 .

[16]  Fu-Kwun Wang,et al.  Evaluating the efficiency of implementing total productive maintenance , 2006 .

[17]  P. De Groote,et al.  Maintenance performance analysis: a practical approach , 1995 .

[18]  Rodney McAdam,et al.  Implementation of total productive maintenance in support of an established total quality programme , 1996 .

[19]  Richard J. Schonberger,et al.  World Class Manufacturing : The Next Decade : Building Power, Strength and Value , 1996 .

[20]  Terry Wireman.  Total Productive Maintenance: An American Approach , 1992 .

[21]  Peter Willmott,et al.  Total Quality with Teeth , 1994 .

[22]  Donna B. Stoddard,et al.  Reengineering the Organization , 1995 .

[23]  Jens Ove Riis,et al.  A situational maintenance model , 1997 .

[24]  Z JuricK,et al.  Money-based overall equipment effectiveness , 2006 .

[25]  M. T. Hides,et al.  Factors affecting successful implementation of total productive maintenance , 1999 .

[26]  Manoj Kumar Tiwari,et al.  Implementing the Lean Sigma framework in an Indian SME: a case study , 2006 .

[27]  D. Tripathi,et al.  Relationship between TQM and TPM implementation factors and business performance of manufacturing industry in Indian context , 2005 .

[28]  G. Ravishankar,et al.  Competitive manufacturing through total productive maintenance , 1992, [1992 Proceedings] IEEE/SEMI International Semiconductor Manufacturing Science Symposium.

[29]  D. Hutchins.  Introducing TPM [total productive maintenance] , 1998 .

[30]  R. Schroeder,et al.  The impact of total productive maintenance practices on manufacturing performance , 2001 .

[31]  Liselott Lycke,et al.  Experience of Implementing TPM in Swedish Industries , 2000 .

[32]  D. Tripathi,et al.  Influence of experience and collaboration on effectiveness of quality management practices , 2005 .

[33]  Trilochan Sastry,et al.  Competitiveness of Indian Manufacturing , 1998 .

[34]  Rambabu Kodali,et al.  Analytical hierarchy process for justification of total productive maintenance , 2001 .

[35]  R. Schroeder,et al.  Relationships between implementation of TQM, JIT, and TPM and manufacturing performance , 2001 .

[36]  F. Cooke.  Implementing TPM in plant maintenance: some organisational barriers , 2000 .

[37]  Shamsuddin Ahmed,et al.  TPM can go beyond maintenance: excerpt from a case implementation , 2005 .