An Agilized Total Productive Maintenance Framework to Reduce Unplanned Downtime
Open AccessUnplanned downtime (UPDT) can be very costly to an organization not only in terms of the tangible costs that are associated with it, but often with the more impactful hidden costs that are factored in. A 2015 Kimberlite study on the impact of UPDT on the oil and gas industry published that “just 1% of unplanned downtime—or 3.65 downtime days per year—can cost organizations $5.037 million each year.” (GE, 2016). With regard to manufacturing operations, this study investigated the negative effects of a lingering UPDT issue on the productivity of a manufacturing plant’s packaging line. The possible root causes were analyzed and they were found to be largely influenced by workforce performance and inadequate maintenance processes. As a result, a total productive maintenance (TPM) approach was deemed the most practical long-term solution to the UPDT problem facing the packaging line under study. To help facilitate the TPM implementation at the line and to maximize its benefits as a continuous process improvement lean tool, an agile management approach was adopted. This approach put an emphasis on Agile team structures operating in an Agile environment to facilitate workflow and problem-solving through teamwork, cross-functional collaboration, maintenance efficiency, and customized or targeted on-demand employee training. The TPM implementation complemented by the agile management approach resulted in the reduction by at least 20% of the persistently excessive UPDT rate of over 40% at the packaging line. Consequently, the OEE score of the line improved from an average 40% to its goal of at least 50%. In essence, the agile management approach enabled the rapid integration of TPM, which enhanced maintenance procedures and line operation processes while optimizing workforce performance in a relatively short period of time. The agilized TPM concept was validated as it helped a manufacturer achieve and maintain a long-term productivity goal in less time than a stand-alone TPM program.
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