Analyzing the Relationship between Total Productive Maintenance (TPM) Practices and the Sustainability of Institutional Performance in Cement Manufacturing Companies

Abstract

This study aims to analyze the operational gap between current maintenance practices and the optimal maintenance level in the industrial sector, with a focus on using the Overall Equipment Effectiveness (OEE) indicator as an evaluative tool. Data were collected from production management records and reports covering the period 2012–2022 to assess the performance efficiency of production equipment at the Libda Cement Plant. The results revealed a significant operational gap between actual performance and the ideal level across various production units, negatively impacting operational efficiency, reliability, and productivity.

Performance indicators varied across the studied units. The storage unit initially achieved high performance but later declined due to increased failure rates. The grinding unit demonstrated gradual improvement in reliability and maintenance efficiency, despite fluctuations in overall performance. The finished product unit experienced sharp fluctuations, with complete performance collapse in certain years—potentially due to catastrophic failures or data recording errors. In contrast, the ground-scale unit showed continuous improvement and outperformed other units in most performance indicators, particularly in 2021. The mixing unit exhibited unstable performance, with only partial recovery in recent years, as failure rates remained high and operational availability suboptimal. These findings highlight the urgent need to develop maintenance strategies and enhance monitoring and analysis systems to bridge the operational gap and achieve sustainable industrial performance.