Difficulties observed when implementing Total Productive Maintenance program (TPM)

Orientador: Rosley AnholonDissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia MecânicaResumo: A busca constante por melhoria competitiva e lucratividade empresarial fez com que atividades de manutenção evoluíssem de ações corretivas para ações integradas corretivas, preditivas e preventivas. Como ferramenta de melhoria contínua, a Manutenção Produtiva Total ou Total Productive Maintenance visa aumentar a confiança no equipamento e eficiência de gestão em todos os níveis de trabalho, integrando produção, manutenção e engenharia. Porém, muitas organizações encontram dificuldades em implantar com sucesso esse modelo estratégico de manutenção, devido à diversas complexidades. O objetivo principal da pesquisa está relacionado à tentativa de comprovar que as dificuldades associadas à adoção do programa TPM se dividem em dois grupos, sendo eles dificuldades associadas à fase de planejamento e dificuldades associadas à fase de implantação. A elaboração e divisão das dificuldades nesses dois grupos foi realizada via painel de especialista, conhecido como Técnica de Grupo Nominal. Para a coleta de dados, foi realizada uma survey com profissionais de empresas brasileiras responsáveis pelo planejamento e implantação do programa em sistemas produtivos. Os dados obtidos foram tratados via análise fatorial confirmatória de segunda ordem por meio da modelagem de equações estruturais, mais precisamente por meio da técnica PLS-SEM. A PLS-SEM pode ser entendida como uma técnica de modelagem para fins exploratórios, sendo chamada de soft modelling. Estudos iniciais apontaram a necessidade de uma amostra mínima de 55 respondentes. Foram obtidas um total de 69 respostas de profissionais de diferentes áreas de atuação, cargos e anos de experiência com o programa TPM. Os resultados obtidos confirmaram a relação causal entre as dificuldades na fase de planejamento e as dificuldades observadas na fase de implantação. Os resultados decorrentes desta dissertação são de extrema valia tanto para profissionais de manutenção e produção quanto para pesquisadores interessados no tema em suas futuras pesquisasAbstract: The search for competitiveness and business profitability led to an evolution of maintenance activities from previously only corrective actions to integrated corrective, predictive and preventive plans. As a continuous improvement tool, Total Productive Maintenance increases confidence and improve work levels by integrating production, maintenance and engineering sectors. However, many organizations face problems in successfully deploying this strategic maintenance model due to various complexities. The main objective of the research is related to the attempt to prove that the difficulties associated with the adoption of the TPM program can be divided into two groups, difficulties associated with the planning phase and difficulties associated with the implementation phase. An elaboration and division of the difficulties in these two groups was carried out by panel of specialists, known as Nominal Group Technique. For data collection, a survey was conducted with professionals from Brazilian companies responsible for planning and implementing the program in productive systems. The data were treated using a second-order confirmatory factorial analysis using the structural equation modelling, more precisely through the PLS-SEM technique. PLS-SEM can be known as a modeling technique for exploratory purposes, whether it is called soft modeling. Initial studies indicated the need for a minimum sample of 55 respondents. A total of 69 responses were obtained from professionals in different areas of performance and years of experience with the program TPM. The results confirmed the causal relationship between the difficulties in the planning phase and the difficulties observed in the implantation phase. The results of this dissertation are of extreme value for maintenance and production professionals as well as for researchers interested in the subject in their future researchMestradoMateriais e Processos de FabricaçãoMestra em Engenharia Mecânica33003017CAPE

Difficulties observed when implementing Total Productive Maintenance (TPM): empirical evidences from the manufacturing sector

This article analyses the difficulties observed in adopting the Total Productive Maintenance (TPM) program in production systems. The research strategies used for this purpose consisted of a literature review, a panel of experts and a survey with professionals working in manufacturing companies. Altogether, 69 market professionals took part in the survey and the collected data was analyzed through the PLS-SEM technique. Results indicate that there is a causal relationship between difficulties associated with the planning phase of a TPM program and issues associated with its implementation. This is an original research and the results are valuable to business professionals desiring to properly implement TPM, as well for researchers interested in the mechanics of total productive maintenance system’s adoption

Industry 4.0 in the product development process : benefits, difficulties and its impact in marketing strategies and operations

Product development process (PDP) in the context of Industry 4.0 may present several marketing implications. To understand these implications, the purpose of this study is to identify the benefits and difficulties of Industry 4.0 related to the PDP and its impact in marketing strategies and operations. The methodology used to perform this research was a systematic literature review. For this, five steps were followed, namely, research question formulation; studies location; studies selection and evaluation; analysis and synthesis; and reporting and use research results. The systematic literature review considering PDP in Industry 4.0 context resulted in 28 benefits and 14 difficulties, in a total of 53 articles. From the analysis of these benefits and difficulties, several implications for marketing were identified, namely, better understand customer preferences; greater agility in marketing decision-making; better align marketing, product development and operations processes issues; better understand product/service lifecycle; analyze possibilities of new ways of distribution and communication channels; better define the value of products and services and location requirements. The findings presented here can be used both by market professionals, interested in the subject and by researchers for future studies. The better understanding of PDP in the context of Industry 4.0 can enhance marketing strategies for market professionals and provide insights for researchers. No similar studies were found in the literature11