Abstract
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 that systematic interventions
regarding TPM deployment have significantly contributed toward improving the manufacturing
system productivity, quality, safety, morale and besides ensuring the cost effectiveness of the
manufacturing function within the organization. The case study reveals that holistic TPM
implementation has lead to establishment of strategic proactive maintenance practices in the
organization for avoiding future system and equipment-related losses, and has marshaled the
organization toward capability building for sustained competitiveness in the global marketplace.
Practical implications – This paper highlights the contributions of maintenance function to ensure
enhanced equipment reliability, thereby affecting improvements in the manufacturing system
performance. In this study the TPM implications in a steel manufacturing plant have been highlighted,
which may be implemented in other manufacturing plants to improve their performance.
Originality/value – The present study encompasses systematic identification of
maintenance-related losses, setting up of targets regarding maintenance performance improvements
and developing guidelines for achieving enhanced manufacturing system performance through
strategic TPM initiatives in the steel manufacturing plant, which can also be important to all
concerned with maintenance and safety in various manufacturing enterprises.
Keywords Productive maintenance, Production equipment, India, Manufacturing systems,
Total quality management
Paper type Case study