Total Quality Management (TQM) and Total Productive Maintenance (TPM) systems are considered as the key operational activities of the quality management system. Implementing TQM and TPM together results in synergy. They act as two drives to improve the business performance excellence in a typical industry. One of the main objectives of TPM is to increase the productivity of plant and equipment with a modest investment in maintenance. After implementing TPM, it is necessary to measure the effectiveness of TPM. Overall Equipment Effectiveness (OEE) is an indicator that measures the effectiveness of TPM. The number of defective products produced by the machine indicates the condition of the machine and also reduces the rate of quality and affects the OEE. In this paper, an attempt is made to measure the effectiveness of TPM by performing a statistical analysis. The assessment of TPM on a continual basis is an essential activity of OEE validation. This activity involves large computations and analytical skills. The estimation of TPM is a time-consuming and costly process. It is not possible to conduct the study very often. If the behavioral pattern of TPM is determined analytically, it helps the maintenance engineer to predict the OEE over a specific period of time. In view of the above, reliability-based TPM estimation is proposed in the paper.

Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production and quality systems through the machines, equipments, processes and employees that add business value to the organization (Ahuja and Khamba, 2008). TPM, when implemented fully, dramatically improves productivity and quality, and reduces the cost. Thus, it is an innovative approach to the maintenance system which optimizes the Overall Equipment Effectiveness (OEE), eliminates breakdowns and promotes the autonomous maintenance through day-to-day activities involving the total workforce. The goal of the TPM program is to enhance the volume of the production, employee morale and job satisfaction.

In any organization, adding additional best practices, such as TPM approach, to operations management is most useful in the development of extra capabilities (McAdam and McGeough, 2000). The TPM is a proactive and cost-effective approach to the equipment maintenance. It maximizes the equipment effectiveness by establishing a comprehensive productive-maintenance system covering the life of the equipment and spanning all equipment-related fields. The philosophies behind TPM are principles of teamwork and empowerment in the form of autonomous maintenance to the productive maintenance techniques (Al-Hassan et al., 2000).

Operations Management Journal, Statistical, Analysis, Reliability, Estimation, Total, Productive, Maintenance.