Enhancing Total Productive Maintenance Strategy for Improved Productivity and Performance

This study aims to enhance total productive maintenance (TPM) in the pipe industry, specifically within a factory in the Amhara region. The objective is to improve productivity and address challenges faced during TPM implementation. Through identifying obstacles, analyzing factors, and exploring strategies, this research provides insights and recommendations for optimizing maintenance practices. Findings emphasize the need for improved productivity and maintenance strategies, highlighting the importance of a team-based approach. The factory mainly focuses on breakdown and preventive maintenance, lacking a comprehensive TPM approach. The computed overall equipment effectiveness (OEE) stands at 38%, below the standard of 85%. To improve efficiency and reduce downtime, losses limiting equipment effectiveness have been addressed. A total productivity model has been developed, emphasizing the study’s significance in enhancing operational performance. Suggested solutions include implementing TPM pillars such as 6S, Autonomous Maintenance, Planned Maintenance, Focused Improvement, Training & Education, Quality Maintenance, Office TPM, and Safety, Health, and Environment, involving management, workers, and maintenance staff. Proposed solutions include training, empowering operators, improving maintenance strategies, and developing a comprehensive TPM implementation plan. Implementing these recommendations will eliminate breakdowns, increase productivity, and improve factory performance.