Maximizing Uptime: Cost-Benefit Analysis and Strategic Implementation of Total Productive Maintenance (TPM) in Modern Industries

Abstract

Purpose: This study looks at both the visible and less obvious benefits of implementing TPM, exploring its impact on costs and operations in modern industrial supply chains. The scope of this work was done with, but not limited to Manufacturing companies, Food and Beverage companies, CPGs and similar large and small scale consumer-facing multinationals. While the tangible benefits of TPM such as reduced downtime, fewer breakdowns, and lower maintenance costs are well-known, the study also highlights important intangible gains. These include enhanced employee morale, reduced turnover, and stronger teamwork. By involving employees in maintenance, TPM gives them a sense of ownership and pride in their work, which leads to greater job satisfaction and better overall performance.

Materials and Methods: Using a mixed-methods approach, the research combines interviews with industry professionals and quantitative data from organizations that have adopted TPM. Insights from plant managers, maintenance staff, and other stakeholders provide valuable context, while key performance metrics such as Overall Equipment Effectiveness (OEE), Mean Time between Failures (MTBF), and Mean Time to Repair (MTTR) quantify the improvements in equipment reliability and productivity achieved through TPM.

Finding: The findings show that TPM enhances OEE by improving equipment availability, performance, and quality. Organizations that implement TPM experience fewer unplanned breakdowns and stoppages, which results in better resource utilization, higher production rates, and greater profitability. By encouraging proactive maintenance, TPM helps employees catch minor issues before they turn into costly problems. Another important benefit of TPM is the positive impact on employee involvement and satisfaction. Involving employees at all levels in maintenance tasks creates a team-oriented culture that boosts engagement. Research suggests that engaged employees show higher productivity, better work quality, and lower absenteeism and turnover. With more reliable equipment, companies can deliver higher-quality products, avoid delays, and improve customer satisfaction.

Unique Contribution to Theory, Practice and Policy: The study concludes that TPM should be viewed as a long-term strategic initiative. Expanding TPM practices beyond production to include areas like logistics, human resources, and administration could help drive a broader cultural shift. Overcoming resistance to change is crucial for TPM’s success, and incorporating Industry 4.0 technologies such as predictive maintenance, IoT sensors, and machine learning can further optimize maintenance, prevent breakdowns, and enhance TPM’s effectiveness. In short, TPM is not just a tool for improving equipment and operational efficiency; it also strengthens organizational culture, boosts employee morale, and enhances customer satisfaction. By integrating TPM with advanced technologies, companies can position themselves for sustainable success in the ever-evolving industrial landscape.