A Systematic Review of Challenges in Implementing TPM (Total Productive Maintenance) in Manufacturing Industries: Identifying Essential Skills for Effective TPM Practice

Today in the competitive manufacturing sector, assuring reliable and efficient equipment performance is essential to achieve optimum production results. Total Productive Maintenance (TPM) provides a well-established framework for maximizing equipment efficiency which leading to numerous benefits including enhanced productivity, lower costs, and recognition through awards (TPM Excellence Award). Notwithstanding, effective implementation of TPM presents major challenges in manufacturing industries, which were identified through a systematic review. 17 Studies from various countries (India, Malaysia, Thailand etc.) and industries (heavy machinery, food processing, energy etc.) were included. Objectives of the study include: (1) Identify and categorize the main challenges critical to the success of TPM implementation; (2) Analyze industry experts’ perspectives on how these challenges can be overcome; (3) Provide a skillset for individuals who aspiring to pursue careers in manufacturing that focus on TPM. The main findings underline the gaps between knowledge and skills possessed by employees, improper leadership and management styles among top management, lack of employee engagement and difficulties associated with process implementation which hinder successful deployment of TPM inside organizations. The review shows important TPM-oriented proficiencies for best practice implementation which comprise awareness of TPM pillars and other related concepts, preventative maintenance practices and OEE (Overall Equipment Effectiveness) calculations among others. The study recommends inculcation of these TPM-related skills in professional development programs and their subsequent inclusion in relevant training initiatives to improve effectiveness as TPM practitioners.