|
Abstract:
|
This thesis presents the methodology of linking Total Productive
Maintenance (TPM) and Quality Function Deployment (QFD). The Synergic
power ofTPM and QFD led to the formation of a new maintenance model named
Maintenance Quality Function Deployment (MQFD). This model was found so
powerful that, it could overcome the drawbacks of TPM, by taking care of
customer voices. Those voices of customers are used to develop the house of
quality. The outputs of house of quality, which are in the form of technical
languages, are submitted to the top management for making strategic decisions.
The technical languages, which are concerned with enhancing maintenance
quality, are strategically directed by the top management towards their adoption
of eight TPM pillars. The TPM characteristics developed through the
development of eight pillars are fed into the production system, where their
implementation is focused towards increasing the values of the maintenance
quality parameters, namely overall equipment efficiency (GEE), mean time
between failures (MTBF), mean time to repair (MTIR), performance quality,
availability and mean down time (MDT). The outputs from production system
are required to be reflected in the form of business values namely improved
maintenance quality, increased profit, upgraded core competence, and enhanced
goodwill. A unique feature of the MQFD model is that it is not necessary to
change or dismantle the existing process ofdeveloping house ofquality and TPM
projects, which may already be under practice in the company concerned. Thus,
the MQFD model enables the tactical marriage between QFD and TPM.First, the literature was reviewed. The results of this review indicated that
no activities had so far been reported on integrating QFD in TPM and vice versa.
During the second phase, a survey was conducted in six companies in which
TPM had been implemented. The objective of this survey was to locate any
traces of QFD implementation in TPM programme being implemented in these
companies. This survey results indicated that no effort on integrating QFD in
TPM had been made in these companies. After completing these two phases of
activities, the MQFD model was designed. The details of this work are presented
in this research work. Followed by this, the explorative studies on implementing
this MQFD model in real time environments were conducted. In addition to that,
an empirical study was carried out to examine the receptivity of MQFD model
among the practitioners and multifarious organizational cultures. Finally, a
sensitivity analysis was conducted to find the hierarchy of various factors
influencing MQFD in a company. Throughout the research work, the theory and
practice of MQFD were juxtaposed by presenting and publishing papers among
scholarly communities and conducting case studies in real time scenario. |