Application of Total Productive Maintenance in a Beverage Manufacturing Company in Ogun State

This study examines the application of Total Productive Maintenance principles in a beverage manufacturing company in Ogun State, South West Nigeria, with the objective of improving equipment effectiveness and reducing production losses. Total Productive Maintenance represents a holistic approach to equipment management that involves production operators in routine maintenance activities, thereby reducing equipment failures, changeover times, and quality-related losses. This research assesses the company's baseline Overall Equipment Effectiveness score across three production lines and identifies the major loss categories contributing to equipment inefficiency. Using a structured implementation framework, the study evaluates the deployment of autonomous maintenance, planned maintenance, and focused improvement pillars over a twelve-month engagement period. Data were gathered through plant audits, equipment downtime records, and interviews with maintenance, production, and management personnel. Results show that the overall equipment effectiveness score improved from fifty-one percent to sixty-seven percent over the study period, driven primarily by reductions in minor stoppage losses and setup time. The study identifies middle management resistance to operator-led maintenance as the principal cultural barrier to implementation. Recommendations include structured change management interventions, revised job descriptions formalising operator maintenance responsibilities, and a performance-linked recognition scheme for autonomous maintenance teams. Keywords: Total Productive Maintenance, Overall Equipment Effectiveness, beverage manufacturing, Ogun State, autonomous maintenance