TOTAL PRODUCTIVE MAINTENANCE

Abstract

This study invaginates the influence of skills on various factors contributing to the effectiveness of Total Productive Maintenance (TPM). TPM is a methodology to equipment maintenance that aims to achieve zero breakdown, zero accident & zero defect. The research focuses on understanding how the skills of maintenance personnel impact specific aspects of TPM implementation. The study employs a heterogeneous approach, for combining quantitative analysis and qualitative insights gathered from industry thinktanks. Surveys are used to assess the skill levels of maintenance personnel, while in-depth interviews provide qualitative data on their experiences and perceptions. The selected factors under investigation include equipment reliability. overall equipment effectiveness (OEE), cost efficiency, and employee satisfaction. Preliminary findings suggest a strong correlation between the proficiency of maintenance personnel and the success of TPM initiatives. Highly skilled individuals demonstrate a positive impact on equipment reliability, leading to improved OEE. Furthermore, effective skill development programs contribute to cost savings through optimized maintenance practices. Employee satisfaction is also positively influenced by enhanced skills, as employees feel more confident and capable in their roles. This research contributes to the existing body of knowledge by highlighting the critical role of skills in TPM effectiveness. The outcomes of this study have practical implications for organizations seeking to enhance their maintenance strategies, emphasizing the importance of investing in skill development programs for maintenance personnel. Objective: This concept focused to evaluate the skills of key factors affecting the effectiveness of TPM. TPM is a dynamic approach for equipment maintenance to emphasizes involvement of all employees to achieve optimal equipment performance. The focus of this research was on understanding how the skills of the workforce contribute to the success of TPM implementation. Methodology: The concept employed a heterogeneous approach, combining quantitative analysis % and qualitative insights. Surveys were distributed to employees involved in TPM vi activities, and in-depth discussions were conducted with key owners. The selected factors under examination included equipment downtime, overall equipment efficiency (OEE), and employee engagement. Key Findings: 1. Skills and Training: There is a direct relation with the level of skills possessed by the workforce and the effectiveness of TPM. Well-trained employees demonstrated a higher ability to identify and address equipment issues promptly, resulting in reduced downtime. 2. Employee Engagement: The study found that employee engagement plays a crucial role in TPM success. Skilled employees were more likely to actively participate in maintenance activities, fostering a culture of continuous improvement and collaboration. 3. Overall Equipment Efficiency (OEE): A positive relationship was identified between workforce skills and OEE. Skilled employees were better equipped to maximize equipment output, contributing to improved overall productivity. 4. Challenges: Despite the positive impact of skills, challenges such as a lack of continuous training programs and limited resources were identified as potential barriers to achieving optimal TPM effectiveness. Recommendations: Based on the observations, the recommendations are suggested to enhance the impact of skills on TPM effectiveness: a. Implement Regular Training Programs: Establish a structured and ongoing training program to enhance the skills of the workforce in line with evolving maintenance requirements. b. Foster a Culture of Continuous Improvement: Encourage a proactive approach to problem-solving and continuous improvement, emphasizing employee involvement and engagement in TPM activities. c. Allocate Sufficient Resources: Ensure that the organization allocates adequate resources, both in terms of time and budget, to support skill development initiatives and TPM implementation.