Critical success factor and barriers in implementation of total productive maintenance

Abstract

Total Productive Maintenance (TPM) focuses in improving machine availability, machine performance efficiency and quality rate which can be key tool for manufacturing companies to survive intense global competition. Poor machine maintenance will lead increase in machine down time that affect the organization’s performance in meeting customer requirement in term of product quality and quantity while increasing the operating and maintenance cost. The purpose of this research is to examine the role of critical success factor in TPM implementation adopting three tools of TPM. It is seen as a solution to increasing machine breakdown at Heimann Sensor Packinging Sdn. Bhd. that caused struggle in meeting customer demand. Besides that, barriers which act as challenges of the TPM implementation also evaluated. Data collected through questionnaire distributed face-to-face to the employees involve in TPM implementation. Regression used to study the relationship between critical success factor and TPM tools performance. Total 108 respondents participated in this survey with 100% response rate. Top management commitment, resources management, work culture and involvement are the critical success factors studied but the analysis proved that only top management commitment, resources management and training and education the critical success factor that enhance the TPM tools performance. TPM tools performance are indicated by autonomous maintenance, planned maintenance and focused maintenance. Resistance to change, improper tooling and poorly managed maintenance data are the barriers identified that need to be addressed during TPM implementation. Implementation of TPM improved the manufacturing performance in overall. As TPM implementation is long term mission measuring TPM tools performance instead of taking big leap to measure OEE during implementation stage will be an effective way to successfully implement TPM.