Identification and analysis of barriers of TPM implementation using total interpretive structural modeling approach: a case study

Abstract

Bangladesh is already entered in the era of modern industrialization, even preparing to enter the 4IR (4th Industrial Revolution). So, we are becoming more export oriented. Above 80% of our export products are ready-made garments. Now a day’s world’s manufacturing industries are going through a very competitive time due to Covid-19 situation. Surviving has become quite difficult. Many industries are trying to adapt some globally used tools and techniques, such as TPM (Total Productive Maintenance), to survive in the competitive market. This is a philosophical tool which mainly focused on to start an autonomous system that combine the manufacturing and maintenance which will prevent losses, reduce costs, and develop a system to properly use the capacity of machines. Some industries are trying their heart and soul to implement TPM. However, most of the industries are not being concern about the barriers of implementing; hence, they fail to take the proper countermeasure and fails to implement. The aim of this research is to identify barriers that are impeding TPM implementation. Initially fourteen barriers were identified and then reduced to ten through analysis and which are mostly related to the RMG sector. After that, a structural model of barriers is suggested using Total Interpretive Structural Modeling (TISM) technique. This model will help to understand contextual relationship among barriers and determined their interdependency. Lastly, MICMAC analysis has been done to determine the importance of barriers based on their driving power and dependency. The findings from this research shows that lack of top management’s involvement and not implementing pilot-study, are the most important among barriers. Some other barriers like lack of education and training, no SOP, lack of KPI based analysis etc. also considered to be significant. These findings and its visual presentation through TISM model will help industrial managers to concentrate on barriers to prevent failure of TPM implementation. They will easily understand where to focus on and what preventive measure could be taken to effectively implement TPM in RMG sector.