Abstract:
Aim of the study is to evaluate how specific TPM pillars impact the production performance of Ok Plastic Factory. The factory currently relies on reactive maintenance, resulting in increased resource demands, overlooked maintenance costs, and significant machine downtime, which negatively affects productivity. Analysis reveals high machine unavailability, as indicated by MTBF and MTTR. Implementation of TPM aligns with government initiatives to support local production and enhance manufacturing performance by improving reliability and reducing downtime. This study focuses on the plastic bottle factory sector, evaluating the impact of TPM techniques such as 5S, Focused improvement, planned maintenance, Autonomous maintenance, and Training and education. It aims to identify adoption barriers, explore influencing factors, and determine the benefits of TPM. This research addresses the lack of quantitative studies on the effects of TPM, contributing valuable knowledge to the field. This study also aims to design and develop a Total Productive Maintenance (TPM) model tailored to the plastic manufacturing industry, with a specific focus on OK Plastic Factory. Primary objective is to enhance the production performance of the factory by implementing TPM strategies. The study employs a survey methodology, achieving a 97% response rate from 35 manufacturing workers, to collect data on production metrics, downtime occurrences, and causes, scrap levels, and rework. Statistical tools are used to establish the relationship between manufacturing performance dimensions and TPM pillars. The results indicate that Planned Maintenance is given the highest priority, while Office TPM receives the least emphasis. The Analytic Hierarchy Process (AHP) is used to validate and support the findings derived from descriptive statistics. The results reveal that the emphasized improvement, planned maintenance, autonomous maintenance, and training and education. This leads to cost reduction, improved flexibility, reliable delivery, and increased equipment availability. A novel model is proposed, integrating the Safety, Health, and Environment (SHE) pillar across all four pillars. This integrated approach not only enhances productivity but also ensures intangible benefits such as safety and well-being within organizations. It is crucial to maintain safety initiatives across all pillars to establish a secure work environment. The findings of this study have a significant impact on improving productivity, reducing costs, enhancing equipment availability, and contributing to safety.
Key words: Total Productive Maintenance, Critical Success Factors, Overall Equipment Effectiveness, Maintenance Performance, TPM pillars.