Total productive maintenance framework for automotive companies in Malaysia

Abstract

Total productive maintenance (TPM) is an extensive maintenance management approach aimed towards improving the overall equipment effectiveness (OEE). A review on literature revealed that current TPM frameworks are generic and have inadequate coverage on the critical success factors (CSFs) constructs in its structure. These frameworks do not address the operational context particularly in providing the guideline for implementation, thus make it incomplete to be used in adopting TPM methodology. This research aims to provide a more comprehensive TPM framework with a set of significant CSFs and guideline for implementation. First, a conceptual framework (denoted as TPM Framework I) was developed with seven significant CSFs constructs as its main components, namely: management commitment and leadership; employee participation; training and education; effective communication; strategic planning; structured implementation approach, and; monitoring and evaluation. It was used for data collection through a mixed method research approach which integrates single-embedded (in-depth) design case study and survey. A methodological triangulation utilizing both qualitative and quantitative methods has been used throughout the research, which includes: semi-structured interview; document analysis; direct and participant observation; analysis of artifacts, and; exploratory survey. The case study aims at providing an insight of how the largest automotive company and six of its subsidiaries implement TPM by exploring “what” and “how” the CSFs constructs are emphasized. Multiple unit of analysis were explored individually and results are drawn together to yield an overall picture of the actual TPM practice. Cross-case analysis and descriptive statistics was used for data analysis. Findings and feedbacks from the case study were synthesized to develop the improved conceptual framework (denoted as TPM Framework II) which was then validated through expert validation involving eight respondents from other automotive companies. The inputs from expert validation were analyzed and incorporated for the development of final conceptual framework (denoted as Final TPM Framework III). It filled the gap of previous research by integrating most aspects of CSFs constructs from both human and operational context. Another novelty of Final TPM Framework III is the inclusion of extensive implementation plan and introduction of new additional structures of CSFs such as: address all eight pillars of TPM; holistic involvement of business stakeholders, and; employees’ skill development linking with equipment life cycle. Such new characteristics have not been addressed in previous TPM framework. Final TPM Framework III can be generalized to automotive companies since it was synthesized from intensive case study and incorporated other automotive companies’ input mainly through expert validation exercises. Final TPM Framework III enables the management of automotive companies to take effective actions in handling issues related to TPM implementation.