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Identification of Key Enablers For Total Productive Maintenance (TPM) Implementation in Indian Smes
Identification of Key Enablers For Total Productive Maintenance (TPM) Implementation in Indian Smes
Identification of Key Enablers For Total Productive Maintenance (TPM) Implementation in Indian Smes
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TPM
Identification of key enablers implementation
for total productive in Indian SMEs
maintenance (TPM)
implementation in Indian SMEs 2611
Abstract
Purpose – The purpose of this paper is to identify the key enabler for total productive maintenance (TPM)
implementation in Indian small and medium enterprises (SMEs) by using graph theoretic approach (GTA).
There are certain enablers for TPM implementation which helps the organization to implement it
successfully. It is very essential to identify the nature and impact of these key enablers.
Design/methodology/approach – A large number of the enablers (27) have identified for TPM
implementation in Indian SMEs from the available literature, questionnaire survey and expert opinion. These
TPM enablers have categorized into six major categories.
Findings – In this research work, the intensity of identifying enablers has been calculated to show their
impact or influence in TPM implementation. The value of intensity of TPM enablers shows the role or impact
of individual enabler in the implementation of TPM in Indian SMEs.
Practical implications – This study provides an easy-to-use methodology for the practical decision makers
in the manufacturing industry to improve their performance by implementing TPM in Indian SMEs.
A detailed methodology has prepared to identify the enablers for TPM implementation in Indian SMEs by
using GTA. This study also explains that how to check the feasibility of an organization to implement TPM in
Indian SMEs successfully.
Originality/value – TPM is an improvement concept which holds the potential to improve manufacturing
organizations, but its implementation is not easy in Indian SMEs. The reason behind the unsuccessful
implementation of TPM in most of the organizations is the ignorance of impact of innumerable enablers
and barriers.
Keywords SME, Matrix, TPM, Digraph, GTA, PF
Paper type Research paper
1. Introduction
The Indian small and medium enterprises (SMEs) are operating in an unsupportive environment
(Singh et al., 2006). The competition among Indian SMEs in this competitive scenario has put the
organizations under paramount pressure to review their traditional system. However, Brah and
Chang (2004) highlighted the importance of total productive maintenance (TPM) to survive in
this increased global competition. The study of Jutla et al. (2002) also concluded that SMEs
account for more than 75 percent of global economic growth in all countries. These SMEs
provides employment to a lot of people and, globally, they constitute approximately 70 percent
Benchmarking: An International
of gross national product (Ammenberg and Hjelm, 2003). The ability of an organization (SMEs Journal
or large) to survive in this global competition depends on how well the organization adapts Vol. 25 No. 8, 2018
pp. 2611-2634
market demands imposed by a changing market scenario to satisfy their customers. © Emerald Publishing Limited
1463-5771
The customer requirement is endless. The satisfaction of customer depends on how the DOI 10.1108/BIJ-02-2016-0019
BIJ organization works. Due to the following reasons, Indian Manufacturing organizations need to
25,8 adopt the improvement technique in SMEs also. There are so many techniques available to
adopt by organizations to survive in this high competition. TPM implementation is also one
important approach to adopt by either large organization or SMEs to improve the performance
of maintenance activities (Ahuja and Kumar, 2009).
In 1971, this term TPM basically originated in Japan as a method for the improvement of
manufacturing performance, maintenance operations and quality of product and services.
2612 One of the renowned researchers in the field of TPM is Nakajima (1988), after his extensive
research has identified TPM as the optimal tool for better maintenance strategies that can be
used to optimize equipment effectiveness, eliminates breakdowns and promotes
autonomous maintenance by total employee’s participation. TPM motivates top
management to take the concept of zero defects, zero breakdowns and minimal
production losses with maximizing equipment effectiveness and stepping up the skills of
operators and maintenance personnel (Kigsirisin et al., 2016).
In most of the cases, production operators are not considered as integral members of the
maintenance team in Indian manufacturing organizations. But in the concept of TPM, the
machine operators should be trained to enhance their skills, so that they can perform basic
simple maintenance or routine maintenance tasks on their machines. Although TPM
implementation gives a drastic improvement in overall manufacturing performance, still
Indian manufacturing industries are facing a lot of challenges in TPM implementation
(Tripathi, 2005; Ahuja and Khamba, 2007, 2008a; Shahanaghi and Yazdian, 2009;
Almeanazel, 2010; Amin et al., 2013; Jain et al., 2015).
The complete knowledge of key Enablers for the top management of an organization is
pre-requisite in the successful implementation of TPM. A questionnaire-based survey was
conducted in the targeted Indian SMEs in north and central India to know about their opinions
and explore their views regarding the key enablers for the successful TPM implementation.
The questionnaire was written in simple English, which can be easily understood by
respondents. In India, the procedure of sending questionnaires and receiving responses
through e-mail is not adequate. To get the reliable responses through questionnaires, the
authors have personally visited each company and explain the purpose of this questionnaire. In
this study, 200 organizations covering electronic/electrical, machine component, textile, food,
printing and packaging industry, and oil industry, chemical industry, rolled product, sugar
mill, fasteners and plastic industry and others have been approached for the evaluation of TPM
strategies in Indian SMEs. This study has included only small and medium manufacturing
organizations of north and central India, not service industries. Total 141 Indian SMEs has
personally visited and received 129 filled questionnaires from the respondents. Out of 129 filled
questionnaires, 114 responses are useful for this study as shown in Table I. These usable
responses have classified on the basis of product manufactured as shown in Table II.
The main objectives of this paper are as follows:
(1) to identify and categorize enablers for TPM implementation in Indian SMEs;
(2) to express enablers in the form of mathematical equations to understand their
impact and influence by using graph theoretic approach (GTA);
(3) to develop a single index representing the strength of these enablers; and
(4) to calculate PF for each enablers to represent key enabler for the considered organization.
Further, in this paper, literature review is presented in Section 2 which describes the study
conducted on identification of enablers for TPM implementation. Methodology, the GTA
approach which includes Digraph representation, matrix preparation, PF calculation and
intensity of TPM enablers (IOETPM) is represented in Sections 3 and 4, respectively. The
results of this research are followed by discussion and conclusions in the last sections.
2. Literature review
The GTA is a technique used for identifying, analyzing and modeling of various kinds of
systems. It is a systematic and logical approach which incorporates the interrelationship
among various elements or sub-system elements and provides a single score for the
evaluation of the entire system. A digraph represents the overall structure of the system and
consist nodes and edges representing characteristics measurement and characteristics
dependencies respectively. Matrix representation is a one-to-one representation of the
digraph. Ahuja and Khamba (2008b) discussed numerous success factors which are
contributing to overcome the challenges posed by global competition in TPM
implementation. The GTA methodology has its versatile applications in so many fields.
The literature regarding the application of GTA in different fields is given in Table III.
The study conducted by Raj et al. (2010b) and Attri et al. (2013) has discussed that the
judging of directional relationship and interrelationship among various enablers can be
made by GTA. These enablers not only help in TPM implementation, but also help each
other to achieve. However, available literature has discussed various barriers, enablers and
benefits of TPM implementation, but no study has attempted to find the intensity of
enablers for TPM implementation in Indian SMEs. The quantification of these enablers by
GTA was also not discussed in the literature. The IOETPM indicates the strength of the
success of TPM implementation.
success in the TPM implementation. Further, Hartmann (2000) has also reported that every
second attempt of TPM implementation is failing. Therefore, associated enablers or barriers
have to be found and analyzed before TPM implementation in order to get success. The
researchers (Attri et al., 2014; Poduval et al., 2015) have analyzed the barriers inhibiting
TPM implementation and the researchers (Raj et al., 2008, 2010b) analyzed enablers for
modeling of flexible manufacturing system. Haleem et al. (2012) also analyzed critical
success factors for world class manufacturing practices, but no study was conducted for
analyzing enablers intensity for TPM implementation.
From the questionnaire survey, literature review and expert decision (discussed with
production and maintenance managers and academicians) a large number of enablers (27)
have identified which helps the implementation of TPM in Indian SMEs successfully. These
enablers are large in number so their quantification is difficult by GTA. To avoid any
difficulty in analyzing, these enablers should be categorize into groups to find their
intensity. Hence, these TPM enablers have categorized into six major categories on the basis
of their effect. Many researchers (Grover et al., 2004, 2005, 2006; Raj and Attri, 2010; Raj
et al., 2010a, b; Anand and Bahinipati, 2012; Muduli et al., 2013) also categorized some factors
into grouped in their work to find the intensity of these factors. The categorization of these
six major enablers and their sub-enablers are as shown in Figure 1.
Moreover the mean (m), standard deviation (SD) and Cronbach’s α (CA) calculations are
used to test the reliability and validity of collecting data for these considered six major
enablers. The values of CA for these enablers are found in the range of 0.692–0.950
(according to Black and Porter, 1996; Nunnally, 1978, the significant value of CA ⩾ 0.65)
which represents the reliability of data is significantly higher. Table IV illustrates the results
of statistical analysis for major enablers. SPSS software is used for this calculation.
The identification of these major enablers is explained in detail as follows.
2.1.1 Human-related TPM enablers (HRTE). These enablers are basically pertaining to
the human resources management in an organization. It includes five sub-enablers as top
management leadership, motivation, total employee involvement, coordination between
departments and employees, and employees empowerment. For the successful
WRTE (E2) TPM
• Computerized
Maintenance
implementation
Management System in Indian SMEs
(CMMS) (E21)
• Team Spirit (E22)
• Work Culture (E23)
• Work Place
Environment (E24) 2615
HRTE (E1) • Attitude Change (E25) MRTE (E3)
• Top Management • Preventive
Leadership (E11) Maintenance (E31)
2 • Autonomous
• Motivation (E12)
• Total Employees Maintenance (E32)
Involvement (E13) • Mobile Maintenance
• Coordination b/w (E33)
1 3 • Availability of tools
Departments (E14)
• Employees and instruments (E34)
Empowerment (E15) • Maintenance
TPM Management (E35)
Enablers
CRTE (E6)
KRTE (E4)
• Quality (E61)
• Educated work force
• Safety, Health and 6 4 (E41)
Environment(E62)
• Education and
• Continuous
Training of
Improvement (E63) 5 Employees (E42)
• Customer
• Long term Planning
Satisfaction (E64)
(E43)
ORTE (E5) • Knowledge about
• Organizational Policy TPM programme
(E51) (E44)
• Availability of space
for work (E52)
• Availability of Figure 1.
Resources (E53)
Key enablers for
• Rewards and
TPM implementation
Incentives (E54)
3. Methodology
In this study, the GTA methodology is used to calculate the IOETPM for TPM
implementation in Indian SMEs. The flow chart of main steps used in this methodology to
find the intensity of Enablers by using GTA is as shown in Figure 2.
Human-related TPM
Ennablers (E1) (HRTE)
2619
E5 E3
Figure 4.
Digraph
representation of key
enablers for TPM
implementation in
E4 Indian SMEs
Here, a single arrow represents the interdependency of one enabler on another and two
arrows represents the mutual interdependence of both the enablers. This interdependency is
the decision of the expert team in this particular considered organization only.
4.3 PF representation
PF is a mathematical expression of TPM enablers in symbolic form. It is a mathematical
model and can be used for calculating the intensity of enablers for TPM implementation.
The PF calculation is same as determinant of matrix calculation but use only positive sign for
all the terms because the negative sign gives the loss of some information
(Rao and Padmanabhan, 2010). Due to this ultimate property, many researchers (Rao, 2004,
2006a, b, c; Rao and Padmanabhan, 2006, 2007, 2010; Kulkarni, 2005; Grover et al., 2006;
BIJ Thakkar et al., 2007; Raj et al., 2010b; Singh and Singru, 2013; Attri et al., 2014) have used this
25,8 PF calculation concept in their study. The general equation of PF for TPM enabler’s matrix
(6×6) can be written as:
Y
6 XXXXXX
Per ðE Þ ¼ Ei þ eij eji ðE k E l E m E n Þ
1 i j k l m n
2620 XXXXXX
þ eij ejk eki þeik ekj eji E l E m E n
i j k l m n
"
XXXXXX
þ eij eji ðekl elk ÞE m E n :
i j k l m n
#
XXXXXX
þ eij ejk ekl eli þeil elk ekj eji E m E n
i j k l m n
"( )
XXXXXX
þ eij eji ðekl elm emk þekm eml elk ÞE n :
i j k l m n
( )#
XXXXXX
þ eij ejk ekl elm emi þeim eml elk ekj eji E n
i j k l m n
"( )
XXXXXX
þ eij eji ðekl elm emn enk þekn enm eml elk Þ :
i j k l m n
( )
XXXXXX
þ eij ejk eki ðelm emn enl Þ
i j k l m n
( )
XXXXXX
þ eij eji ðekl elk Þðemn enm Þ
i j k l m n
( )#
XXXXXX
þ eij ejk eki elm emn eni þein enm eml elk ekj eji : (2)
i j k l m n
8 9 Sub enablers E 1i
>
> 9 3 4 4 4>
>
>
> >1
>
>
<4 7 0 0 4>
>
>
=
n
E1 ¼ 0 0 8 2 3 2 : (3)
>
> >
>
>
> 0 0 3 6 >3
4>
>
> >
>
: ;
4 3 0 3 9 4
5
BIJ Human related TPM Inheritance and Work related TPM Enablers Inheritance and
Enablers Interdependencies Interdependencies
25,8
E11 = 9, E12 E21 = 6, E22
= 7, E13 = 8, E14 E21 = 7, E23 = 8, E24
E11
= 6, E15 = 9, = 8, E25 = 9,
e112 = 3, e113 e212 =1, e213
E15 = 4, e114 = 4, e115 E25 E22 = 2, e214 = 2, e223
E12
2622 = 4, e121 =4, e125 = 4, e224 = 4, e225
= 4, e134 = 2, e135 = 3, e232 = 3, e234
= 3, e143 = 3, e145 = 4, e242 = 4, e243
E13 E24 E23 = 4, e245 = 2, e252
E14 = 4, e151 =4, e152
= 3, e253 = 3, e254
= 3, e154 = 3
=3
Maintenance related TPM Inheritance and Knowledge related TPM Inheritance and
Enablers Interdependencies Enablers Interdependencies
= 4, e15
3 = 4, e3
21 = 2, e414 = 3, e421
E35 E32
= 2, e23
3 = 3, e25
3 = 4, e423 = 2, e424
= 4, e3 = 3, e35
32 E44 E42
3 = 3, e434
= 3, e3 = 3, e3
41 42
= 2, e441= 3, e442
= 4, e43
3 = 3, e3
45
= 3, e443 = 2
E34 E33 E43
= 3, e51
3 = 2, e3
52
=2
Organization related TPM Inheritance and Customer related TPM Inheritance and
Enablers Interdependencies Enablers Interdependencies
2623
Table VI.
Responses of
Note: Responses are on the basis of scale of inheritance and interdependence expert team
Enablers/
sub-enablers E1 E2 E3 E4 E5 E6 e1 e2 e3 e4 e5 e6
Mean 7.0 7.6 7.4 7.5 8.0 7.5 3.46 3.0 3.07 2.8 3.0 2.75
Standard
deviation (SD) 1.58 1.14 0.89 1.29 0.82 1.29 0.66 0.96 0.73 0.79 0.58 0.71 Table VII.
Coefficient of Summary of
variation (in %) 22.6 15 12 17.2 10.25 17.2 19.1 32 23.8 28.2 19.33 25.8 responses of experts
BIJ Similarly, the matrix for other TPM Enablers can be written as:
25,8 8 9 Sub enablers E 2i
>
> 6 1 2 2 0 >
>
>
> >
> 1
>
> 0 7 4 4 3 >
>
< =
E n2 ¼ 0 3 8 4 0 2 ; (4)
>
> >
>
>
> 0 4 4 8 2 >
> 3
2624 >
> >
>
: ;
0 3 3 3 9 4
5
8 9 Sub enablers E 3i
>
> 8 3 4 0 4> >
>
> >
> 1
>
> 2 8 3 0 4 >
>
< =
E n3 ¼ 0 3 7 0 3 2 ; (5)
>
> >3
>3 4 3 6 3>
> >
>
>
> >
>
: ;
2 2 0 0 8 4
5
8 9 Sub enablers E 4i
> 8 4 2 3>
>
> >
>
<4 9 2 3=1
E n4 ¼ 2 ; (6)
>
> 0 0 6 2>>
>
: >
;3
3 3 2 7
4
8 9 Sub enablers E 5i
> 7 0 3 2>
>
> >
>1
< 0 6 3 0=
E n5 ¼ 2 ; (7)
>2
> 3 8 4>>
>
: >
;3
3 0 2 9
4
8 9 Sub enablers E 6i
> 7 4 3 2>
>
> >
>
<0 8 3 0=1
E n6 ¼ 2 : (8)
>
> 0 0 9 3>>
>
: >
;3
3 0 3 8
4
The value of a PF for HRTE can be calculated by using equation (2). The value of E1* is:
Per E n1 ¼ 9 7 8 6 9 þ9 7 8 4 3 þ9 7 3 9 2 þ9 7 3 3
3 þ9 3 4 8 6 þ9 3 3 4 2 þ4 3 8 6 9 þ4 3
8 4 3 þ4 3 3 2 9 þ4 3 3 3 3 þ4 3 4 2
4 þ4 3 4 6 3 þ4 4 4 8 4 þ4 3 4 3 3 þ4
TPM
3 4 8 6 þ4 3 4 3 2 þ4 3 4 8 6 þ4 3 4 3 implementation
2 þ4 7 4 2 4 þ4 7 4 6 3 þ4 7 4 8 4 þ4 7
in Indian SMEs
4 3 3 þ4 7 4 8 6 þ4 7 4 3 2 ¼ 70;899:
Similarly, the values of PF of other sub-system level enablers are calculated and given as: 2625
PerðE n2 Þ ¼ 59;832; PerðE n3 Þ ¼ 40;880; PerðE n4 Þ ¼ 5;690; PerðE n5 Þ ¼ 5;292; PerðE n6 Þ
¼ 4;452:
The system-level matrix can be obtained by replacing diagonal elements with the values of a
PF of sub-system level:
E 1 ¼ Per E n1 ¼ 70;899; E 2 ¼ Per E n2 ¼ 59;832; E 3 ¼ Per E n3 ¼ 40;880;
E 4 ¼ Per E n4 ¼ 5;690; E 5 ¼ Per E n5 ¼ 5;292; E 6 ¼ Per E n6 ¼ 4;452:
And the values of interdependencies at the system level are taken as similar as taken at sub-
system levels. These values are:
e12 ¼ 4; e13 ¼ 3; e14 ¼ 2; e15 ¼ 3; e16 ¼ 3; e23 ¼ 3; e26 ¼ 2; e32 ¼ 3; e36 ¼ 3;
The PF of this matrix is calculated by using PF Equations (2) and is found to be 2.6 × 1025.
This value of PF shows the intensity of enablers for TPM implementation (IOETPM) in the
considered organization. Since, the inheritance of each Enabler has calculated at sub-system
level by using GTA. Therefore, the value of inheritance for Enabler at system level
depending upon its sub-enablers. First, calculate maxima and minima of PF at the
sub-system level by assuming the hypothetical maximum (9) and minimum (1) values of
diagonal elements, respectively. For example, maxima of the PF value for HRTE exist when
inheritance of each sub-enabler is maximized, i.e. 9, and the minima exists when inheritance
of each sub-enabler is minimized, i.e. 1 ( from the scale of 1–9 for inheritance). Therefore, the
matrix for each TPM Enablers for its maximum and minimum values is as shown in
Figure 6.
Now the values of (IOETPM)max and (IOETPM)min are calculated by replacing diagonal
elements of matrix at system level as given in Equation (9) by these maximum and
minimum values of inheritance of the particular category. The final matrixes for
(IOETPM)max and (IOETPM)min are given by the following equations, respectively.
BIJ Enablers Maximum value Minimum value
25,8 9 3 4 4 4 1 1 3 4 4 4 1
Human related
TPM Enablers
4 9 0 0 4 2 4 1 0 0 4 2
*
(E1 )max = 0 0 9 2 3 *
(E1 )min = 0 0 1 2 3
(HRTE)
3 3
0 0 3 9 4 4 0 0 3 1 4 4
4 3 0 3 9 5 4 3 0 3 1 5
Per (E1)max =165,786 Per (E1*)min = 6,490
9 1 2 2 0 1 1 1 2 2 0 1
2626 TPM Enablers
Work related
0 9 4 4 3 2 0 1 4 4 3 2
(WRTE) (E2*)max = 0 3 9 4 0 (E2*)min = 0 3 1 4 0
3 3
0 4 4 9 2 4 0 4 4 1 2 4
0 3 3 3 9 5 0 3 3 3 1 5
Per (E2*)max =125,847 Per (E2*)min = 2,175
9 3 4 0 4 1 1 3 4 0 4 1
Enablers (MRTE)
2 9 3 0 4 2 2 1 3 0 4 2
Maintenance
related TPM
(E3*)max = 0 3 9 0 3 3
*
(E3 )min = 0 3 1 0 3 3
3 4 3 9 3 4 3 4 3 1 3 4
2 2 0 0 9 5 2 2 0 0 1 5
Per (E3*)max = 92,664 Per (E3*)min = 407
9 4 2 3 1 1 4 2 3 1
related TPM
4 9 2 3 2 4 1 2 3 2
Knowledge
(E4*)max = (E4*)min =
Enablers
(KRTE)
0 0 9 2 3 0 0 1 2 3
3 3 2 9 4 3 3 2 1 4
(E5*)max = 0 9 3 0 2 (E5*)min = 0 1 3 0 2
Enablers
(ORTE)
0 0 9 3 3 0 0 1 3 3
3 0 3 9 4 3 0 3 1 4
Figure 6.
Customer
0 9 3 0 2 0 1 3 0 2
Enablers
(CRTE)
(E6*)max = (E6*)min =
Maximum and 2 3 9 4 3 2 3 1 4 3
minimum values for 3 0 2 9 4 3 0 2 1 4
TPM enablers Per (E6*)min =128
Per (E6*)max = 9,360
ðIOETPM Þmax ¼ E n max
8 9
>
> 165;786 4 3 2 3 3 >
> 1
>
> >
>
>
> 0 125;847 3 0 0 2 >
> 2
>
> >
>
>
<0 >
=3
3 92;664 0 0 3
¼ ; (10)
>
> 2 4 3 10;563 0 2 >4
>
>
> >
>
>
> 0 0 2 3 9;027 1 >
>
>
> >
> 5
>
:0 >
;
3 0 1 0 9;360 6
8 9
> 6;490 4 3 2 3 > 1 3
>
> >
>
>
> 0 2;175 3 0 0 >
> 2 2
>
> >
>
>
<0 >
=3
3 407 0 0 3
ðIOETPM Þmin ¼ E n min ¼ : (11)
>2
> 4 3 259 0 2 >>4
>
> >
>
>
> 151 1 >>
>
> 0 0 2 3 >
> 5
: ;
2 3 0 1 0 128 6
The value of Per (E*)max and Per (E*)min are 1.63×1027 and 2.8×1016, respectively. These are TPM
called the maximum and minimum IOETPM, which indicate the range within which they implementation
can vary. The maximum, minimum and current values of PF for enablers at the system and in Indian SMEs
sub-system levels are given in Table VIII.
5. Discussion
This paper presents a methodology to evaluate the feasibility/suitability of TPM 2627
implementation in Indian SMEs. This is based on the influence of enablers. These enablers
have been obtained through the questionnaire survey, available literature, and expert
opinion. In total, 114 usable responses were obtained from top management of various
Indian SMEs. A medium-size organization has been considered to demonstrate the proposed
methodology. In this research work, the intensity of various TPM enablers has been
calculated by using a GTA methodology to know their influence on TPM implementation in
Indian SMEs. PF is used to obtain the intensity of these enablers. Out of total six TPM
Enablers, the HRTE has maximum intensity for the considered medium-size organization.
Top management leadership, motivation, total employee involvement, coordination between
departments and employees empowerment play a significant role in TPM implementation at
the sub-system level. Many researchers have already explained the importance of top
management in TPM implementation. It is the duty of the top management of the
organization to motivate their employees either by empowering them or by giving some
incentives, rewards so that the participation of employees can increase in the TPM
implementation program. The top management should come forward to make the strategy
on the basis of the intensity of these enablers to implement TPM effectively.
The next important enabler is WRTE, which indicated that the CMMS, team spirit, work
culture, workplace environment, attitude change also play a significant role in TPM
implementation in Indian SMEs. Literature available on the TPM Implementation has
already discussed the necessity of these sub-enablers in TPM Implementation. Work culture
and workplace environment can enhance the willingness of employees to take part in TPM
Implementation. The attitude of employees should be positive so that they can think
positively. Employees should show willingness instead of resistance to adopt TPM.
And the next important category of enabler is MRTE. The maintenance programs as
Preventive maintenance, Autonomous maintenance, and Mobile maintenance should be
strongly implemented in an organization for implementing TPM. Maintenance department
should be sufficiently staffed and motivated in the maintenance program. Tools and
instruments for the maintenance of machines must be available, and the most important
thing is that the expenditure incurred on maintenance tasks should be monitored and
optimized. It is the duty of the production head to motivate their subordinates to take part in
maintenance task and also to establish an autonomous maintenance program.
Subsequent enabler categories are KRTE and ORTE. The training of employees should
be conducted on a regular basis for educating them and providing knowledge about TPM
and its benefits. Also, the organizational policy should be transparent for everybody to get
promotion, any rewards or incentives. The last enabler of this study is CRTE. Quality
plays a significant role in customer satisfaction. Nowadays, customer satisfaction is
needed to survive in this competitive environment which can only be possible by
PF Per E n1 Per E n2 Per E n3 Per E n4 Per E n5 Per E n6 Per E*
Table VIII.
Maximum value 165,786 125,847 92,664 10,563 9,027 9,360 1.63 × 1027 Interval for maxima
Minimum value 6,490 2,175 407 259 151 128 2.8 × 1016 and minima
Current value 70,899 59,832 40,880 5,690 5,292 4,452 2.6 × 1025 of PF values
BIJ continuous improvement. Safety, health and environment are also playing a vital role in
25,8 TPM implementation.
Since the value of Per (E*) at the system level represents the intensity of enablers for
implementing TPM in Indian SMEs, Table VIII illustrates that the current value of PF for
enablers at the system and sub-system level is very nearer to the corresponding maximum
value and very far from the corresponding minimum value. This comparison is
2628 mathematically characterized the feasibility/suitability of any organization to implement
TPM successfully based on the availability of these enablers and their interdependencies.
6. Conclusions
TPM implementation is a capital investment intensive and complex system. In order to get
the best economic benefits, procedure and implementation of TPM should carefully be
decided. A high level of maturity on the part of top management is required for successful
implementation of TPM in Indian SMEs. Motivation, total employee involvement,
employee empowerment, team spirit, positive attitude, various maintenance systems,
education and training, available resources, etc., are also the key enablers at the
sub-system level in this research. Therefore, it becomes necessary to understand
the nature of various enablers and their impact on the implementation of TPM in Indian
SMEs successfully.
In this research, a methodology has been proposed to evaluate the feasibility/
suitability of TPM implementation in the considered organization by using GTA. GTA is
both qualitative and quantitative methods for modeling the manufacturing system of any
organization to bring it feasible/suitable for TPM implementation. It helps in modeling the
various TPM enablers and their interdependency. The PF calculation gives a single
numerical value (i.e. IOETPM ) for this considered organization. A manufacturing system of
Indian SMEs can also be compared with knowing their PF values for the feasibility/
suitability of TPM implementation. It is recommended to calculate the value of PF for
selected few organizations which are using the TPM concept in a useful manner and also
set their range to get the optimal result by using this GTA methodology. The organization
which is highly interested to adopt the TPM concept, the IOETPM at the system level
should be calculated. If the value of IOETPM lies within the predefined set range, then it
should found to be suitable for TPM implementation, and if not, then it should be
compared with an organization in which TPM has been successfully implemented.
The value of the IOETPM should also be compared at the sub-system level and improve
weak enablers and again evaluate the value of IOETPM at the system level. Now, if this
value is within the required range, then the organization should be considered as being
feasible/suitable for TPM implementation.
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Corresponding author
Abhishek Jain can be contacted at: abhi_mpct@rediffmail.com
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