Enhancing Lean Performance through TPM–VSM Integration: A Case Study in Spare Parts Production

Abstract

In today’s highly competitive manufacturing landscape, achieving Lean Manufacturing Excellence is critical for maximizing efficiency, minimizing costs, and enhancing customer satisfaction. This study examines the strategic integration of Total Productive Maintenance (TPM) and Value Stream Mapping (VSM) to optimize spare parts production. TPM enhances equipment reliability through proactive maintenance, while VSM streamlines material and information flows to eliminate waste and improve process efficiency. Conducted in the machining process of an Egyptian spare parts manufacturing company, this research develops a robust framework leveraging advanced analytical and improvement methodologies. A data-driven case study quantifies the impact of TPM-VSM synergy, demonstrating significant performance gains. Over three months, implementation increased Total Effective Equipment Performance (TEEP) from 58% to 68%, improved Overall Equipment Effectiveness (OEE) from 65% to 76%, and elevated value-added process efficiency from 37% to 54%. These results validate the effectiveness of integrating Lean methodologies with proactive maintenance strategies to drive productivity, minimize waste, and sustain operational excellence. This study provides a practical framework for industry professionals seeking to foster continuous improvement, data-driven decision-making, and Lean-driven optimization in spare parts manufacturing.