Inderpreet Singh Ahuja

Total productive maintenance: literature review and directions

Purpose – The purpose of this paper is to review the literature on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices adopted by the manufacturing organizations. It also seeks to highlight appropriate enablers and success factors for eliminating barriers in successful TPM implementation.Design/methodology/approach – The paper systematically categorizes the published literature and then analyzes and reviews it methodically.Findings – The paper reveals the important issues in Total Productive Maintenance ranging from maintenance techniques, framework of TPM, overall equipment effectiveness (OEE), TPM implementation practices, barriers and success factors in TPM implementation, etc. The contributions of strategic TPM programmes towards improving manufacturing competencies of the organizations have also been highlighted here.Practical implications – The literature on classification of Total Productive Maintenance has so far been very limited. The paper reviews a larg...

An evaluation of TPM implementation initiatives in an Indian manufacturing enterprise

Purpose – The purpose of this study is to identify maintenance‐related losses for ascertaining and addressing the performance losses, and affecting improvements in the manufacturing performance in an organization through strategic total productive maintenance (TPM) initiatives.Design/methodology/approach – In this paper TPM initiatives in the steel manufacturing plant have been elaborated to ascertain the tangible and intangible benefits accrued as a result of successful TPM implementation. The approach has been directed toward justification of TPM implementation for its support to competitive manufacturing in the context of Indian manufacturing industries.Findings – The paper establishes the long‐term effects of TPM on organizational performance in the Indian context. TPM implementation initiatives have shown marked improvements in the equipment efficiency and effectiveness, and have also brought about appreciable improvements in other manufacturing functions in the organization. It has been observed tha...

An evaluation of TPM initiatives in Indian industry for enhanced manufacturing performance

Purpose – The purpose of this paper is to evaluate the contributions of total productive maintenance (TPM) initiatives towards improving manufacturing performance in Indian Manufacturing Industry.Design/methodology/approach – In this study, a large number of manufacturing organizations have been extensively surveyed, to ascertain contributions made by TPM initiatives in the Indian manufacturing industries towards realizing manufacturing performance improvements. The correlations between various TPM implementation dimensions and manufacturing performance improvements have been evaluated and validated by employing various statistical tools.Findings – The research focuses upon the significant contributions of TPM implementation success factors like top management leadership and involvement, traditional maintenance practices and holistic TPM implementation initiatives, towards affecting improvements in manufacturing performance in the Indian industry. The inter‐relationships between various TPM implementation...

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...

Total Productive Maintenance

Manufacturing organizations worldwide are facing many challenges to achieve successful operation in today’s competitive environment. Modern manufacturing requires that, to be successful, organizations must be supported by both effective and efficient maintenance practices and procedures. The global marketplace has necessitated many organizations to implement proactive lean manufacturing programs and organizational structures to enhance their competitiveness (Bonavia and Marin, 2006). Over the past two decades, manufacturing organizations have used different approaches to improve maintenance effectiveness. One approach to improving the performance of maintenance activities is to develop and implement strategic TPM programs (Ahuja and Khamba, 2007). Among various manufacturing programs, Total Quality Management (TQM), Just-in-Time (JIT), Total Productive Maintenance (TPM) and Total Employee Involvement (TEI) programs have often been referred to as components of “World Class Manufacturing” (Cua et al. 2001).

A case study of total productive maintenance implementation at precision tube mills

Purpose – The purpose of this paper is to investigate the contributions of successful total productive maintenance (TPM) initiatives to competitive manufacturing. It also seeks to critically examine the implications of strategic TPM implementation initiatives in an Indian manufacturing organisation.Design/methodology/approach – The study is carried out at a precision tube mill that has successfully implemented TPM and has reaped significant benefits as a result of TPM implementation, to study the TPM implementation issues and achievements realised as a result of strategic TPM implementation. The approach is directed towards the justification of TPM implementation for its support to competitive manufacturing in Indian industries.Findings – The study reveals the exploits of Indian entrepreneurs with TPM practices and highlights the contributions of TPM in realising the overall organisational goals and objectives. The study reveals that strategic TPM initiatives can significantly contribute towards the impro...

Assessment of contributions of successful TPM initiatives towards competitive manufacturing

– The purpose of this paper is to investigate the contributions of successful TPM initiatives to competitive manufacturing. It also seeks to critically examine implications of strategic TPM implementation initiatives in Indian manufacturing organizations., – A reasonably large number of manufacturing organizations with successful experience of TPM initiatives have been surveyed to assess the contributions of strategic TPM practices to accruing manufacturing competencies. The study involves working out the correlations between various TPM success factors and manufacturing competencies for extracting contributions of significant factors towards realization of manufacturing competencies., – It was found that mere adoption of TPM initiatives does not lead organizations to garner strategic manufacturing competencies. The study highlights that holistic TPM initiatives have a significant impact on the realization of strategic manufacturing competencies in organizations. These interrelationships can be used to understand the effect of various TPM success factors on the realization of an organizations objectives of growth and sustainability., – The study has been conducted to develop an understanding of contributions of TPM initiatives towards building manufacturing competencies in the Indian manufacturing industry. The study investigates manufacturing performance achievements accrued through strategic TPM success factors in the Indian manufacturing industry., – The study identifies the impact of key TPM success factors on organizational performance and highlights the need for successfully managing TPM programmes for establishing sustained maintenance improvement initiatives., – The paper stresses the need for strategically managing TPM programmes successfully in organizations in order to realize the true potential of TPM practices for meeting global competition.

Justification of total productive maintenance initiatives in Indian manufacturing industry for achieving core competitiveness

Purpose – The purpose of this paper is to develop an understanding of contributions of total productive maintenance (TPM) initiatives towards building core competencies in Indian manufacturing industry. This paper critically examines the implications of TPM implementation initiatives in Indian manufacturing organizations.Design/methodology/approach – In this study a large number of manufacturing organizations have been extensively surveyed to ascertain contributions made by TPM initiatives in the Indian manufacturing industries towards realizing core competencies. The study involves working out the correlations between various TPM implementation dimensions and core competencies, and employs various statistical tools for extracting significant factors contributing effectively towards realization of core competencies.Findings – The study reveals that organizational leadership and involvement, traditional maintenance practices, successful adaptation of effective TPM initiatives can significantly contribute t...

An empirical investigation of dynamic capabilities in managing strategic flexibility in manufacturing organizations

Purpose – The purpose of this paper is to evaluate the relative impact of dynamic capabilities on various dimensions of strategic flexibility in Indian manufacturing industry. Design/methodology/approach – In this study, 102 manufacturing organizations have been extensively surveyed, to assess the relative impact of different dynamic capabilities on various dimensions of strategic flexibility. The correlations between dynamic capabilities and strategic flexibility have been evaluated and validated by employing various statistical tools. Findings – The research focuses upon the significant contributions of dynamic capabilities such as human resource capabilities, innovative capabilities, technological capabilities, alliance capabilities and research and development capabilities, towards managing flexibility at strategic level in manufacturing organizations. Originality/value – This study provides the first empirical evidence of such a relationship with a relative choice between dynamic capabilities for man...

Improved Organizational Behavior Through Strategic Total Productive Maintenance Implementation

The manufacturing industry has experienced an unprecedented degree of change in the highly competitive and dynamics manufacturing scenario. Recent competitive trends have been pushing manufacturing executives to reconsider the impact and importance of increasing equipment availability and utilization, maintenance productivity and resource utilization, and increasing quality and responsiveness of maintenance services in meeting overall goals to achieve World Class status. TPM has been envisioned as an effective tool in the quest for achieving the world class status and meeting the ever increasing competition. This paper elaborates the contribution of TPM implementation towards improvement in organizational behavior in the Indian process industry in the quest to attain world-class competitiveness and sustainability efforts. The case study of TPM implementation though team building in Indian process industry has been brought out through the presentation of TPM benefits at the Hot Strip Mill division at a steel manufacturing company. The various aspects of TPM implementation have also been illustrated with the help of a case study.Copyright