Purpose – Total productive maintenance (TPM) is a very powerful program of equipment maintenance in manufacturing industries and is a direct part of total quality management (TQM). In the manufacturing industry, TPM is a very effective tool for improving product quality as well as productivity. A good number of manufacturing industries have so far adopted a TPM program in countries like Japan, as a part of their quality drive. However, in many manufacturing industries in India it has not been successfully implemented. For successful and effective implementation of TPM in manufacturing industries in India, understanding and awareness of the various possible causes behind its failure is essential. This paper aims to address this issue. Design/methodology/approach – In this general review paper, after reviewing literature the authors consolidate, highlight and classify the probable reasons responsible for the failures of TPM in many Indian manufacturing industries. Findings – In this paper, the various causes of failure of TPM in a number of manufacturing industries have been classified into three major categories of problems or issues at three different stages: organizational issues during the foundation stage; TPM implementation issues during the formation stage; and operational issues during the TPM running stage. Practical implications – The recommended guidelines may definitely contribute to the Indian industry and also industries in other developing countries in Asia, Latin America and Africa. Consequently, the work has economic and commercial impacts. Economic, because it would allow to improve the productivity of the companies, and commercial, because it would facilitate the interchange and the positioning of products. In addition, it can have a high impact on the industrial relations of the workers and unions. Originality/value – If management is aware of such probable problems, and becomes careful about them, the TPM programme can also be widely and effectively adopted in many Indian manufacturing industries, and they can achieve improvement in business competitiveness through improved product quality and increased productivity.
Asian Journal on Quality – Emerald Publishing
Published: Aug 24, 2012
Keywords: Total quality management; Total productive maintenance; Productivity; Productive maintenance; Manufacturing industries; India