Mapping barriers to TPM 4.0 implementation through a two-stage fuzzy approach

Purpose This study investigates the barriers to implementing Total Productive Maintenance (TPM) in the context of Industry 4.0 (TPM 4.0). It employs a synthesis of existing literature and theoretical frameworks to delineate key barriers. Design/methodology/approach The research utilizes Fuzzy Interpretive Structural Modeling (FISM) and Fuzzy Decision-Making Trial and Evaluation Laboratory (FDEMATEL) methodologies to identify significant barriers hindering TPM 4.0 implementation. Findings The results indicate that behavioral barriers, stemming from resistance to change and lack of adaptation to new technologies, pose substantial barriers to TPM 4.0 implementation. Organizational barriers, including inadequate senior management commitment and poor communication, further impede the effective execution of TPM initiatives. Technological barriers, such as the absence of computerized maintenance management systems and insufficient real-time monitoring data, present additional barriers to integrating TPM with Industry 4.0 technologies. Social implications Effective implementation of TPM 4.0 can lead to improved operational efficiency, reduced maintenance costs and better utilization of resources, which can have positive social implications in terms of sustainability and economic growth. Originality/value The novelty of this research lies in the simultaneous application of two fuzzy-based multi-criteria decision-making tools (FISM and FDEMATEL), which has not been previously employed for TPM 4.0 in the context of Industry 4.0. This dual-framework enables not only classification but also causal inference regarding barrier dynamics, which is a methodological contribution to the field.