Optimizing Preventive Maintenance to Improve Operational Efficiency and Reduce Maintenance Costs - Review Article
Abstract
The Total Productive Maintenance (TPM) approach is one of the main operational strategies to improve production efficiency and reduce maintenance costs. This article reviews the important role of TPM components, especially the Planned Maintenance System (PMS) and Computerized Maintenance Management System (CMMS), in supporting operational performance. The implementation of these systems involves structured data collection and systematic analysis to improve predictive and preventive maintenance. This article also highlights the success factors and obstacles to implementing TPM, PMS, and CMMS, including management commitment, employee training, technology integration, and challenges such as resistance to change and system complexity. The review results show that cross-functional collaboration, a continuous improvement mindset, and the use of advanced technology are the keys to success in optimizing equipment maintenance, reducing downtime, and increasing operational efficiency and cost effectiveness. Across reviewed studies, operational efficiency increased by 12–35% and maintenance costs decreased by 10–30% after adopting TPM, PMS, or CMMS. These findings emphasize the critical role of digital integration and proactive culture in maintenance optimization.
##Keywords:##
Total productive maintenance (TPM), Planned Maintenance system (PMS), Computerized Maintenance Management System (CMMS).
Published
Nov 30, 2025
How to Cite
ILHAM, Muhammad; MAINIL, Rahmat Iman.
Optimizing Preventive Maintenance to Improve Operational Efficiency and Reduce Maintenance Costs - Review Article.
Journal of Ocean, Mechanical and Aerospace -science and engineering-, [S.l.], v. 69, n. 3, p. 198-206, nov. 2025.
ISSN 2527-6085.
Available at: <https://www.isomase.org/Journals/index.php/jomase/article/view/483>. Date accessed: 30 may 2026.
doi: http://dx.doi.org/10.36842/jomase.v69i3.483.
References
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[22] Gunathilaka, N. V., Tennakoon, W., & Lasanthika, W. (2021). Factors affecting the success of computerized maintenance management system in multinational beer companies. https://www.sab.ac.lk/sujcs/.
[23] Sukmana, F., & Rozi, F. (2024). Efficiency of CMMS project stages with K-means. JIPI: Scientific Journal of Informatics Research and Learning, 9(1), 424–437. https://doi.org/10.29100/jipi.v9i1.5453.
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[32] Aniki, A.O., Akinlabi, E.T. (2013). Implementation of CMMS Software for a Maintenance Plan in a Manufacturing Industry. International Journal of Mechanical, Industrial Science and Engineering, 7, 85-88.
[33] Fumagalli, L., Macchi, M., & Rapaccini, M. (2009). Computerized maintenance management systems in SMEs: A survey in Italy and remarks for the implementation of condition-based maintenance. IFAC-PapersOnline, 1615–1619. https://doi.org/10.3182/20090603-3-RU-2001.0416.
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[35] Björling, S.-E., Galar, D., Baglee, D., Singh, S., & Kumar, U. (2013). Maintenance knowledge management with fusion of CMMS and CM.
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[38] Shagluf, A., & Longstaff, A. P. (2014). Maintenance strategies to reduce downtime due to machine positional errors. In Proceedings of Maintenance Performance Measurement and Management (MPMM) Conference (pp. 111–118). https://doi.org/10.14195/978-972-8954-42-0_16.
[39] Almomani, H., & Aldaihani, A. H. (2021). Using Computerized Maintenance Management System (CMMS) in Roads Maintenance Operations. International Journal of Environmental Science, 6.
[40] Amorim, E., Silva, E., & Lordsleem, A., Jr. (2024). Current overview of CMMS operationality: Brazilian scenario. International Journal of Business Administration, 14(4), 66. https://doi.org/10.5430/ijba.v14n4p66.
[41] Wienker, M., Henderson, K., & Volkerts, J. (2016). The computerized maintenance management system: An essential tool for world-class maintenance. Procedia Engineering, 413–420. https://doi.org/10.1016/j.proeng.2016.02.100.
[2] San, S. (2021). A systematic literature review of total productive maintenance on industries. Performance: Industrial Engineering Scientific Media, 20(2), 97. https://doi.org/10.20961/performa.20.2.50087
[3] Ngoy, K. R., & Israel, K. (2021). The strategy of successful total productive maintenance (TPM): Implementation and benefits of TPM (literature review). International Journal of Innovation Research in Engineering, Multidisciplinary, and Physical Sciences, 9, 43-52.
[4] Duffuaa, S. O., & Al-Shayea, M. M. (2020, July). Systematic and effective maintenance capacity planning. In 2020 Industrial & Systems Engineering Conference (ISEC) (pp. 1-4). IEEE.
[5] Amorim, E., Silva, E., & Lordsleem, A., Jr. (2024). Current overview of CMMS operationality: Brazilian scenario. International Journal of Business Administration, 14(4), 66. https://doi.org/10.5430/ijba.v14n4p66.
[6] Sianturi, G., & Alatas, H. (2019). Analisis Efektivitas Mesin Injection Molding Di Bagian Produksi Pt. Dian Megah Indo Perkasa Menggunakan Metode Overall Equipment Effectiveness Dan Fault Tree Analysis. Inaque: Journal of Industrial and Quality Engineering, 7(2), 127-136.
[7] Mutaqiem, A., & Soediantono, D. (2022). Literature review of total productive maintenance (TPM) and recommendations for application in the defense industry. Journal of Industrial Engineering & Management Research, 3(2), 48-60.
[8] Muhaemin, G., & Nugraha, A. E. (2022). Implementation of total productive maintenance (TPM) in cutter machine maintenance at PT. XYZ. Scientific Journal of Educational Vehicle, 8(9), 205–219. https://doi.org/10.5281/zenodo.6645451.
[9] Krisnaningsih, E. (2015). Proposal for implementing TPM to improve machine effectiveness with OEE as a measurement tool at PT XYZ. PROSISKO Journal, 2(2).
[10] Gianfranco, J., Taufik, M. I., Hariadi, F., & Fauzi, M. (2022). Measurement of total productive maintenance (TPM) using overall equipment effectiveness (OEE) on production reactor machines. Lingkar Biru, 3(1). https://doi.org/10.46306/lb.v3i1.
[11] Hidayat, D. F., Hardono, J., & Wijaya, W. A. (2020). Total productive maintenance (TPM) analysis using overall equipment effectiveness (OEE) on a CNC milling machine. http://jurnal.umt.ac.id/index.php/jt/index.
[12] Diniaty, D., & Susanto, R. (2017). Analisis Total Produktive Maintenance (Tpm) Pada Stasiun Kernel Dengan Menggunakan Metode Overall Equipment Effectiveness (Oee) Di Pt. Surya Agrolika Reksa. Jurnal Teknik Industri, 3(2), 60-64.
[13] Karim, M. R. (2025). Optimizing Maintenance Strategies in Smart Manufacturing: A Systematic Review Of Lean Practices, Total Productive Maintenance (TPM), And Digital Reliability. Review of Applied Science and Technology, 4(02), 176-206.
[14] Nurdin, F. F. (2023). Peningkatan Produktivitas Peralatan dan Perawatan Mesin Total Productive Maintenance (TPM) menggunakan metodeOverall Equipment Effectiveness (OEE). Prosiding Sains dan Teknologi, 2(1), 388-399.
[15] Zaenal Arifin, S. T. (2020). Implementasi Overall Equipment Effectiveness (OEE) Dalam Penerapan Metode Total Productive Maintenance (TPM) di PT. FJT. PROFISIENSI: Jurnal Program Studi Teknik Industri, 8(1), 55-63.
[16] Idrus Taba, M., & Hakim, H. (2022). The effect of total productive maintenance (TPM) and lean manufacturing (LM) maintenance systems on overall equipment effectiveness (OEE) (Case study at PT. Semen Tonasa). SEIKO: Journal of Management & Business, 5(1), 2022–393. https://doi.org/10.37531/sejaman.v5i2.2039.
[17] Prabowo, R. F., Hariyono, H., & Rimawan, E. (2020). Total Productive Maintenance (TPM) pada perawatan mesin grinding menggunakan metode overall equipment effectiveness (OEE). Journal Industrial Servicess, 5(2), 207-212.
[18] Heri Londong Allo, H. L. A. (2022). Efektifitas Planned Maintenance System (PMS) Mesin Induk Mv. Ace Oscar (Final Project, Politeknik Ilmu Pelayaran Makassar).
[19] Prabowo, R., & Sulistyowati, E. (2020, July). Analysis of Total Productive Maintenance (TPM) and Failure Mode and Effect Analysis (FMEA) to improve machine effectiveness: A study on Indonesia’s sugar mills. In IOP Conference Series: Materials Science and Engineering (Vol. 885, No. 1, p. 012063). IOP Publishing.
[20] Majid, A. M., Moengin, P., & Witonohadi, A. (2014). Usulan penerapan total productive maintenance (tpm) dengan pengukuran overall equipment effectiveness (oee) untuk perencanaan perawatan pabrik bar mill pada PT. Krakatau Wajatama. Jurnal Teknik Industri, 4(3).
[21] Nursubiyantoro, E., & Rozaq, M. I. (2016). Implementation of total productive maintenance (TPM) in the application of overall equipment effectiveness (OEE). Jurnal OPSI, 9(1).
[22] Gunathilaka, N. V., Tennakoon, W., & Lasanthika, W. (2021). Factors affecting the success of computerized maintenance management system in multinational beer companies. https://www.sab.ac.lk/sujcs/.
[23] Sukmana, F., & Rozi, F. (2024). Efficiency of CMMS project stages with K-means. JIPI: Scientific Journal of Informatics Research and Learning, 9(1), 424–437. https://doi.org/10.29100/jipi.v9i1.5453.
[24] Meira, D., Lopes, I., & Pires, C. (2020). Selection of computerized maintenance management systems using AHP. Procedia Manufacturing, 1573–1580. https://doi.org/10.1016/j.promfg.2020.10.219.
[25] Labib, A. W. (2004). A decision analysis model for maintenance policy selection using a CMMS. Journal of Quality in Maintenance Engineering, 10(3), 191–202. https://doi.org/10.1108/13552510410553244.
[26] Febrihartina, S. S., Sholihah, W., & Irawan, B. (2019). Pembuatan Modul User Dan Master Data Pada Aplikasi CMMS Berbasis Web di PT Bit Maker Automation. Jurnal Sains Terapan: Wahana Informasi dan Alih Teknologi Pertanian, 9(1), 1-16..
[27] Stazi?, L., Ra?i?, N., Stanivuk, T., & Dobrota, ?. (2023). Determination of benefits of the application of CMMS database improvement proposals. Applied Sciences, 13(4). https://doi.org/10.3390/app13042731.
[28] Witonohadi, A., & Timothy, I. (2011). Usulan Perbaikan Sistem Perawatan Mesin dengan Pendekatan Computerized Maintenance Management System (CMMS) di PT. NTP. Teknik dan Manajemen Industri, 6(2), 80-86.
[29] Azahar, N. F. (2017). Study of Technology Acceptance of Computerized Maintenance Management Systems (CMMS) as a Tool for Measuring Contractor's Performance: A Case Study of Public Work Department, Putrajaya (Master's thesis, University of Malaya (Malaysia)).
[30] Mansouri, Z., Sarir, H., & Mahboub, O. (2019, October). MCDM-Review of Decision Making Modules Integration in CMMS. In Proceedings of the 4th International Conference on Big Data and Internet of Things (pp. 1-4).
[31] Chairiyah, W., Syakhroni, A. S., Sukendar, I. S., & Raya Kaligawe, J. K. (2019). Design of machine maintenance information system with CMMS approach (Case study of PT. PMKS-BPJ). Proceedings of UNISSULA Students’ Scientific Conference (KIMU) 2.
[32] Aniki, A.O., Akinlabi, E.T. (2013). Implementation of CMMS Software for a Maintenance Plan in a Manufacturing Industry. International Journal of Mechanical, Industrial Science and Engineering, 7, 85-88.
[33] Fumagalli, L., Macchi, M., & Rapaccini, M. (2009). Computerized maintenance management systems in SMEs: A survey in Italy and remarks for the implementation of condition-based maintenance. IFAC-PapersOnline, 1615–1619. https://doi.org/10.3182/20090603-3-RU-2001.0416.
[34] Mobin, M. Maintenance Decision Making, Supported By Computerized Maintenance Management System. Organization, 6, 193.
[35] Björling, S.-E., Galar, D., Baglee, D., Singh, S., & Kumar, U. (2013). Maintenance knowledge management with fusion of CMMS and CM.
[36] Rodrigues, R. C., Sousa, H., & Gondim, I. A. (2023). SMARTS-based decision support model for CMMS selection in integrated building maintenance management. Buildings, 13(10). https://doi.org/10.3390/buildings13102521.
[37] Shankar, L., Singh, C. D., & Singh, R. (2024). AI and CMMS: A powerful duo for enhanced maintenance in manufacturing. Educational Administration: Theory and Practice, 30(5), 8647–8654. https://doi.org/10.53555/kuey.v30i5.4434.
[38] Shagluf, A., & Longstaff, A. P. (2014). Maintenance strategies to reduce downtime due to machine positional errors. In Proceedings of Maintenance Performance Measurement and Management (MPMM) Conference (pp. 111–118). https://doi.org/10.14195/978-972-8954-42-0_16.
[39] Almomani, H., & Aldaihani, A. H. (2021). Using Computerized Maintenance Management System (CMMS) in Roads Maintenance Operations. International Journal of Environmental Science, 6.
[40] Amorim, E., Silva, E., & Lordsleem, A., Jr. (2024). Current overview of CMMS operationality: Brazilian scenario. International Journal of Business Administration, 14(4), 66. https://doi.org/10.5430/ijba.v14n4p66.
[41] Wienker, M., Henderson, K., & Volkerts, J. (2016). The computerized maintenance management system: An essential tool for world-class maintenance. Procedia Engineering, 413–420. https://doi.org/10.1016/j.proeng.2016.02.100.
