Total Productive Maintenance and its Effecting on the Application of Lean Production System

Increasing the amount of production, the diversity of products, a commodity and / or service, and increasing the productivity factor ratios contribute to developing the competitive strength of the organization in light of the increasingly difficult market conditions. That made all organizations work according to competitive strategies, including the production strategy for the purpose of achieving the organizations goal through the set of goals that they put. They rely on several new management systems of a strategic nature aimed at their survival and continuity in the production market. Hence, this research aims to evaluate the total productivity maintenance capacity in lean production throughout reducing the various kinds of losses, as the lean production is based on reducing each defective product (a commodity and / or service), costs, errors, and area, and all that and others aimed at improving product quality and customer satisfaction. However, the overall goals and production programs often encounter unexpected breakdowns at unexpected times, which lead to a breakdown in production and an imbalance in production plans as a result. Consequently, the companies suffer the expected revenue loss because they fail to reach the targeted production amount. The research has adopted a questionnaire that has been distributed to (50) employees of the General Company for Electric Power Production, the central region in Baghdad, which constituted more than 10% of the company’s employees. The results show that there is a strong direct relationship between the independent variable (total productivity maintenance) and the dependent variable (lean production). This distinction has explained 90% of the variables in the dependent variable.

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Lean production practices and bundles: a comparative analysis

International Journal of Lean Six Sigma ◽

10.1108/ijlss-01-2017-0002 ◽

2018 ◽

Vol 9 (3) ◽

pp. 374-398 ◽

Cited By ~ 9

Author(s):

Saumyaranjan Sahoo ◽

Sudhir Yadav

Keyword(s):

Quality Management ◽

Total Quality Management ◽

Business Performance ◽

Management Practices ◽

Lean Production ◽

Business Strategies ◽

Total Quality ◽

Total Productive Maintenance ◽

Content Type ◽

Lean Practices

PurposeTotal productive maintenance and total quality management are two lean manufacturing initiatives that are used by manufacturing plant managers to improve operations capabilities. The purpose of this paper is to investigate the effects of standalone lean practices and lean bundles on manufacturing business performance.Design/methodology/approachA quantitative approach was used. The survey data were drawn from 160 manufacturing organizations in India. The respondent companies were grouped on the basis of the duration of lean production in operation and then classified based on the profile of their operations strategy. The approach, based on comparative assessment between standalone lean practices and lean bundles, has been directed toward justification of lean bundles for its support to competitive manufacturing in the context of the Indian manufacturing sector.FindingsThe paper establishes the long-term effects of lean bundles in significantly improving manufacturing business performance as compared to standalone lean practices. Further findings of the study revealed the significance of the duration of lean production in operation in achieving higher levels of manufacturing business performance.Research limitations/implicationsThe study is cross-sectional in nature. It would be interesting to test the analytical framework adopted for this study for more industries and in different countries. The use of subjective measures in survey questionnaire is also another limitation of the study.Practical implicationsThis study offers clear implications for practitioners, proving that they should give higher emphasis on the implementation of lean bundles using total productive maintenance and total quality management practices together, to prioritize their product, production and business strategies, to achieve sustainable competitive advantage.Originality/valueThis paper empirically examines and evaluates the effect of lean practices and bundles in the context of medium- and large-sized manufacturing industries in India. Besides, there are very few studies that comparatively assess the differences in performance contribution of various lean operational strategies considering duration of implementation of lean. Also, the theoretical contribution of the study establishes the essence of integrating total productive management and total quality management for attaining world class manufacturing is of high value.

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Comparative Study of TQM Practices between Japanese and Non-Japanese Companies: Proposed Conceptual Framework

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.903.371 ◽

2014 ◽

Vol 903 ◽

pp. 371-377 ◽

Cited By ~ 9

Author(s):

Mohd Fauzi Ahmad ◽

Norhayati Zakuan ◽

Ahmad Jusoh ◽

Shari Mohd Yusof ◽

Josu Takala ◽

...

Keyword(s):

Conceptual Framework ◽

Business Performance ◽

Lean Production ◽

Critical Factor ◽

Total Quality ◽

Total Productive Maintenance ◽

Statistical Process ◽

Global Marketplace ◽

Japanese Companies ◽

Tools And Techniques

In todays highly competitive market, the demand for quality is a critical factor for organization to survive in the ever-expanding global marketplace. The concept of total quality management (TQM) has been developed as a result of intense global competition. Japanese companies have had superior achievement, and left their counterparts, non-Japanese far behind. One of the TQM strength practices in Japanese companies is technical aspects; tools and techniques namely statistical process control (SPC), total productive maintenance (TPM) and lean production. The purpose of this paper is to compare TQM practices between Japanese and non-Japanese companies, and develop the conceptual framework based on extensive review of the literature. Three theories; institutional theory, system theory and contingency theory have been identified and applied in this study for developing conceptual framework. Based on literature review, Japanese companies have higher TQM practices compared to non-Japanese companies. Furthermore, this study proposes that SPC, TPM and lean production are mediators for TQM in Japanese companies. This proposed research will help the academicians and industry players to have better understanding of TQM implementation in order to improve business performance effectively in the future.

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On Manufacturers’ Strategies for Green Production an Example of the Copper Clad Laminate Industry

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1073-1076.1203 ◽

2014 ◽

Vol 1073-1076 ◽

pp. 1203-1207

Author(s):

Tian Sheng Wu ◽

An Bang Qi ◽

Sang Bing Tsai ◽

Jiann Jong Guo

Keyword(s):

Economic Development ◽

Performance Analysis ◽

Environmental Protection ◽

Technological Progress ◽

Competitive Strategies ◽

Research Project ◽

Green Consumption ◽

Production Processes ◽

Green Production ◽

Production Plans

Green production plans on production processes based on the principle of benefiting ecological and environmental protection, and manufacturers green products to satisfy green consumption. The contents of green production, which in essence is a constantly perfecting process, will keep updating and advancing with technological progress and economic development. Importance-Performance Analysis, IPA, is a methodology frequently used to evaluate performances and enhance competitive strategies. By IPA, this research project evaluated the performance of the firm under study in green production, which was intended as the basis for improvement by the same firm.

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TPS-LAS MODEL USING PROCESS LAYOUT CAE SYSTEM AT TOYOTA: ADVANCED TPS, KEY TO GLOBAL PRODUCTION STRATEGY NEW JIT

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686706000790 ◽

2006 ◽

Vol 05 (02) ◽

pp. 127-140 ◽

Cited By ~ 6

Author(s):

HIROHISA SAKAI ◽

KAKURO AMASAKA

Keyword(s):

21St Century ◽

Production System ◽

Lean Production ◽

Manufacturing Technology ◽

Just In Time ◽

Core System ◽

Digital Factory ◽

Management Technology ◽

Production Strategy ◽

Cae System

Recently, Japanese enterprises have been promoting global production to realize uniform quality worldwide and production at optimal locations for severe competition. The authors attempt to propose New JIT (Just in Time) as a new management technology principle for manufacturing in the 21st century. Therefore, this paper concentrates on verifying the effectiveness of the authors' proposed Advanced TPS to success in global production by excellent manufacturing technology as the key to New JIT at Toyota. So far, the authors have established strategic manufacturing technology for the Lean Production called TPS-LAS (Toyota Production System - Process Layout Analysis Simulation) by using Process Layout CAE System. TPS-LAS model contains the three-core system with logistics investigation simulation, digital factory simulation and workability investigation simulation.

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The Power of ROFO Principle Together with Companywide Training in Executing Lean Production Strategy

International Education Studies ◽

10.5539/ies.v8n11p88 ◽

2015 ◽

Vol 8 (11) ◽

pp. 88 ◽

Cited By ~ 1

Author(s):

Ah Bee Goh ◽

Nopasit Chakpitak ◽

Pradorn Sureephong

Keyword(s):

Lean Production ◽

Production Strategy ◽

Corrective Actions ◽

A Chain

This paper reports the findings of the case study conducted at Schaffner Thailand (ST) factory regarding the application of the ROFO principle coupled with companywide training on the execution of Lean Production (LP) strategy. The case study was motivated by 3 main objectives: 1) to examine the effectiveness of the ROFO principle and companywide training on the execution of LP strategy, 2)to study whether there were significant improvements in productivities between periods I and II, and 3) to assess whether ROFO principle had influenced significantly in changing the mindset of the staff. Companywide training was carried out on 3 modules: the ROFO principle, 5S and Lean Production (LP) concepts. The training of the 3 modules was implemented in period II (2008 to 2012) but not in period I (2003 to 2007). The methods used were survey, interview, and observations. The findings fully support the 3 objectives. The results were encouraging as productivities were not only improved in period II but also the willingness mindset of the staff. This is the power of the ROFO principle as each cycle of the ROFO principle resulted in a chain of corrective actions and learning.

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Characteristics of Mexican Leather Footwear Industry and its International Trade Activity, Correlation of Productivity, and Competitiveness

European Scientific Journal ESJ ◽

10.19044/esj.2018.v14n22p63 ◽

2018 ◽

Vol 14 (22) ◽

pp. 63

Author(s):

Y. D. Cisneros-Reyes ◽

J. E. Rocha-Ibarra ◽

M. G. Arredondo-Hidalgo

Keyword(s):

Latin American ◽

Firm Level ◽

Intermediate Inputs ◽

Goods And Services ◽

Footwear Industry ◽

Pearson Coefficient ◽

Productivity Factor ◽

Production Value ◽

Total Productivity ◽

Productivity And Competitiveness

This paper focuses on analyzing the globalization effect on the Mexican leather footwear industry at a firm-level. In this work, the analysis of competitiveness is done based on the definition given by the Organization for Economic Cooperation and Development (OECD). They defined it as ‘a measure of a country's advantage or disadvantage in selling its products in international market’. The productivity of the Mexican leather footwear industry was calculated using the Latin American-KLEMS Model that relates gross output to primary (Capital and Labor) and intermediate inputs (Energy, Other intermediate goods, and Services). Furthermore, firms were categorized considering the number of employees, the annual value of production, and the commercial diversification in order to calculate the correlation Pearson coefficient. Firstly, the results show that the correlation of production value with the number of exporting companies is bigger than the correlation of the importing companies. Secondly, that the correlation of Total Productivity Factor (TPF) to exports is strong (0.7028); and finally, that the correlation of Total Productivity Factor (TPF) to imports is also significant (0.6511).

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Lean production of ship-pipe parts based on lot-sizing optimization and PFB control strategy

Kybernetes ◽

10.1108/k-06-2019-0389 ◽

2020 ◽

Vol ahead-of-print (ahead-of-print) ◽

Author(s):

Fuli Zhou ◽

Panpan Ma ◽

Yandong He ◽

Saurabh Pratap ◽

Peng Yu ◽

...

Keyword(s):

Control Strategy ◽

Programming Model ◽

Lot Sizing ◽

Lean Production ◽

Sizing Optimization ◽

Content Type ◽

Loop Control ◽

Work In Process ◽

Production Strategy ◽

Part Production

Purpose With an increasingly fierce competition of the shipbuilding industry, advanced technologies and excellent management philosophies in the manufacturing industry are gradually introduced to domestic shipyards. The purpose of this study is to promote the lean management of Chinese ship outfitting plants by lean production strategy. Design/methodology/approach To promote the lean implementation of Chinese shipyards, the lean practice of ship-pipe part production is highlighted by lot-sizing optimization and strategic CONWIP (constant work-in-process) control. A nonlinear programming model is formulated to minimize the total cost of ship-pipe part manufacturing and the particle swarm optimization (PSO)-based algorithm is designed to resolve the established model. Besides, the pull-from-the-bottleneck (PFB) strategy is used to control ship-pipe part production, verified by Simulink simulation. Findings Results show that the proposed lean strategy of the programming model and strategic PFB control could assist Chinese ship outfitting plants to leverage competitive advantage by waste reduction and lean achievement. Specifically, the PFB double-loop control strategy shows better performance when there is high productivity and the PFB single-loop control outperforms at lower productivity scenarios. Practical implications To verify the effectiveness of the proposed lean strategy, a case study is performed to validate the formulated model. Also, simulation experiments realized by FlexSim software are conducted to testify results obtained by the constructed programming model. Originality/value Lean production management practice of the shipyard building industry is performed by the proposed lean production strategy through lot-sizing optimization and strategic PFB control in terms of ship-pipe part manufacturing.

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ممارسات متنوعة في قياس عامل الإنتاجية الكلية للعراق: دراسة تحليلية للمدة (1970-2017)

Iraqi Journal of Economic Sciences ◽

10.31272/ijes2021.71.2 ◽

2021 ◽

Vol 2021 (71) ◽

pp. 19-59

Author(s):

م. نزار صديق الياس

Keyword(s):

Economic Growth ◽

Resource Utilization ◽

Technological Development ◽

Political Instability ◽

The United States ◽

Total Production ◽

Important Indicator ◽

Dummy Variable ◽

Productivity Factor ◽

Total Productivity

The index of the total productivity factor is one of the most important measures expressing the efficiency of resource use, and an important indicator of technological development among the countries of the world. His great contribution to economic growth reveals his ability to lead economic growth. The strong negative changes taking place in the total factor productivity of the country confirm a series of successive events such as the decline in economic growth (negative growth), for example the decline in total productivity during the Great Depression of 1929, and the slowdown in total productivity in the United States of America in the seventies. On the other hand, achieving distinct real economic growth means improved efficiency and performance and a clear rise in the efficiency of resource utilization accompanied by a distinctive technological development for the country concerned, as has happened in China for the past two decades. It was revealed to us by measuring the growth in the total productivity factor of Iraq in the long term, and after using five diverse productivity functions through which (calculating economic growth) was applied, and using three methods (formulas) for each of the five functions and they are; (Solo remainder, regression, and Ferguson's dummy variable method for instability), we have fifteen time series of TFP growth. It has become clear that the calculation of the total productivity factor suffers from a (technological illusion), and there is no technological development in Iraq for the period (1979-2003), at the very least, as "it became clear to us that there is a clear weakness in the contribution of the factor of total productivity to economic growth," and it became clear that the efficiency of resource utilization did not rise to the level of ambition, and the reason is mainly due to political instability, accompanied by the misuse and distribution of resources, which contributed to the deterioration of the economic and social conditions of Iraq specifically during the period (1980-2017). It was also found that the dummy variable of political instability has taken many forms and continuously influencing, was reflected in the fluctuation of growth values in the factor of total productivity calculated by methods and formulas, totaling fifteen practices of the total production function. The successive political events with their diversity were a concomitant characteristic and negatively affecting the Iraqi economic growth during the mentioned period.

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