Implementation of total productive maintenance in large manufacturing firms in Kenya

Abstract

The objective of this study was to establish the challenges, success factors and benefits of implementing Total Productive Maintenance (TPM) in large manufacturing firms in Kenya. The study employed cross-sectional survey design. The population of the study was 201 large manufacturing firms in Nairobi as per Kenya Association of Manufacturers & Exporters Directory: 2013. The study used primary data which was collected through questionnaires. Data was analyzed and presented using descriptive statistics. The study found out that large manufacturing firms in Kenya that implemented TPM, encountered several challenges such as employees considering TPM activities as additional work, insufficient understanding of the methodology and philosophy of TPM implementation, lack of rights skills, top management support, lack of commitment, insufficient resources esp. financial support, among others. The study was able to establish the success factors for the implementation of TPM in large manufacturing firms, and these were, top management commitment, effective communication before and during TPM implementation, support from the shop floor (union staff), training of operators in basic maintenance skills among others. The following were stated by the large manufacturing firms as benefits of implementing TPM: elimination of waste and losses, reduction of equipment breakdown, reduction of maintenance costs, optimization of equipment reliability, improvement of operator skills, boosting morale of employees, among others. This study provides useful insights for the implementation of TPM as a tool that enhances performances. In the current competitive market, large manufacturing firms stand to benefit greatly by adapting TPM as an performance improvement tool.