This study focused on implementation of Total Productive Maintenance (TPM) in geothermal power plants in Kenya. The purpose of this study was to establish the success factors, benefits and challenges faced when implementing total productive maintenance in geothermal power plants in
Kenya.
A descriptive survey design was used in this study. The population comprised all geothermal power plants in Kenya which are Well heads, Olkaria 1, Olkaria 2, Olkaria 3 and Oserian. The population of the respondents was all maintenance and operations staff due to their day to day application of TPM.
The population totaled to 146 staff. A census was used to sample the population since all power plants were being studied giving a sample of 73 staff. The study used primary data which was collected by use of a 5 point Likert scale structured questionnaire administered through a drop and pick later method. Out of the 73 questionnaires provided for data collection, only 59 were returned forming a response rate of 80.8%. The data collected was analyzed by use of descriptive statistics which included mean and standard deviation.
The findings and results of this study proved that there were TPM success factors and benefits in the geothermal power plants as recognized in other industries such as manufacturing and processing firms. These factors are: top management commitment, effective communication, integration of TPM goals to organizational strategy, total employee involvement, education and training, teamwork, tracking machine related problems and carrying out design activities during equipment planning. The study also showed challenges of TPM as failure to implement TPM fully, resource restrictions for operations and maintenance and cultural resistance to change.
The recommendations made included top management adoption of responsibilities which are establishing a favorable environment, communicating the TPM implementation plan and integrating TPM goals to the overall organizational strategy. Top management should also revise their remuneration and recognition strategies so as to improve worker morale. All success factors, benefits and challenges can be emphasized by the leadership role of top management when implementing TPM as they guarantee results in the long run. The study suggested further research on TPM and how it affects organizational performance in geothermal and other modes of power production such as hydro, thermal and wind.