A case study on the application of TPM techniques in the manufacturing industry

Year : 2026 | Volume : 16 | Issue : 01 | Page : 1 9
    By

    Sibabrata Mohanty,

  • Faisal Sagiruddin Shaikh,

  • Fahad Al Akram,

  • Sipu Gochhayat,

  • Pappu Mandal,

  1. Associate Professor, Department of Mechanical Engineering, Gandhi Institute of Excellent Technocrats, Ghangapatna, , India
  2. B.Tech final year students, Department of Mechanical Engineering, Gandhi Institute of Excellent Technocrats, Ghangapatna, , India
  3. B.Tech final year students, Department of Mechanical Engineering, Gandhi Institute of Excellent Technocrats, Ghangapatna, , India
  4. B.Tech final year students, Department of Mechanical Engineering, Gandhi Institute of Excellent Technocrats, Ghangapatna, , India
  5. B.Tech final year students, Department of Mechanical Engineering, Gandhi Institute of Excellent Technocrats, Ghangapatna, , India

Abstract

The steel sector has developed dramatically during recent years, driven by technical breakthroughs, competitive challenges, and changing client requirements. Consumers now place increasing focus on cost effectiveness, shorter delivery lead times, and consistently excellent product quality, driving industrial organizations to continually strengthen their operational performance. Adopting structured quality and maintenance systems has become crucial for maintaining competitiveness and attaining operational excellence in response to these difficulties.With a focus on enhancing work quality, equipment dependability, and overall productivity via the methodical implementation of TPM pillars, this research assesses the effects of Total Productive Maintenance (TPM) efforts on Power & Steel Ltd.’s manufacturing performance. By incorporating workers at all organizational levels, TPM aims to maximize equipment effectiveness and promote a culture of proactive maintenance and continuous development. The goal of the study is to investigate how TPM techniques affect important performance metrics including production efficiency, defect minimization, and downtime reduction.

An extensive case study was carried out at a Power & Steel Ltd. production site in order to verify the efficacy of the suggested strategy. Production records, maintenance logs, and quality reports were used to gather data both before and after TPM installation in order to evaluate changes in operational performance. The implementation of TPM pillars showed promising results, such as decreased equipment failures, higher overall productivity, better process stability, and improved product quality.

The findings suggest that rather than being seen as an extra operational expense, maintenance should be seen as a strategic expenditure meant to increase productivity. Effective maintenance procedures help businesses to maximize asset utilisation, decrease waste, and increase process dependability, consequently increasing their competitive position in the market. Additionally, TPM helps create a workplace that is safer, cleaner, and more organized, all of which have a favorable impact on employee engagement and morale.The report also cites a number of crucial success criteria for TPM adoption, such as the active participation of top management, strong leadership commitment, and the integration of traditional maintenance procedures with complete TPM programs. The success of TPM programs was shown to be further enhanced by employee training, cross-functional coordination, and ongoing performance monitoring. All things considered, the results validate TPM as a workable and successful approach to attaining sustainable manufacturing competitiveness in the Indian steel sector, providing insightful information for researchers and practitioners looking to enhance operational performance via structured maintenance excellence.

Keywords: Total Productive Maintenance (TPM), manufacturing systems, industrial performance, productive maintenance, and overall equipment effectiveness (OEE).

[This article belongs to Journal of Production Research & Management ]

How to cite this article:
Sibabrata Mohanty, Faisal Sagiruddin Shaikh, Fahad Al Akram, Sipu Gochhayat, Pappu Mandal. A case study on the application of TPM techniques in the manufacturing industry. Journal of Production Research & Management. 2026; 16(01):1-9.
How to cite this URL:
Sibabrata Mohanty, Faisal Sagiruddin Shaikh, Fahad Al Akram, Sipu Gochhayat, Pappu Mandal. A case study on the application of TPM techniques in the manufacturing industry. Journal of Production Research & Management. 2026; 16(01):1-9. Available from: https://journals.stmjournals.com/joprm/article=2026/view=238588


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Regular Issue Subscription Original Research
Volume 16
Issue 01
Received 22/01/2026
Accepted 02/02/2026
Published 13/02/2026
Publication Time 22 Days
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