Critical Review of Sri Lankan Tyre Companies on How Their Plant Maintenance Strategy Works

Abstract

The tyre manufacturing industry plays a critical role in the industrial sector of Sri Lanka, contributing significantly to export earnings, employment, and technological advancement. As a capital-intensive, process-driven industry, effective plant maintenance strategies are essential for operational efficiency, product quality, safety, and long-term sustainability. This study critically reviews plant maintenance strategies adopted by six leading Sri Lankan tyre manufacturing companies.  The study examines how these organizations design, plan, implement, and monitor their maintenance frameworks, focusing on proactive maintenance, which includes preventive maintenance, predictive maintenance, reliability-centred maintenance (RCM), total productive maintenance (TPM), and Industry 4.0 technologies. It evaluates their effectiveness in minimizing downtime, optimizing asset utilization, reducing maintenance costs, and ensuring compliance with safety and environmental standards.

Using a mixed-methods approach integrating quantitative and qualitative techniques, this study draws on primary and secondary data, including industry reports, structured questionnaires, semi-structured interviews, focus group discussions, and comparative case analysis. This approach identifies best practices, operational challenges, and strategic gaps in the maintenance management systems of the selected tyre manufacturers. The findings examine the relationship between maintenance strategy maturity and overall manufacturing performance, and provide recommendations to enhance maintenance effectiveness, sustainability, technological integration, and the competitive advantage of the Sri Lankan tyre manufacturing sector. The paper concludes that production pressures and manaement’s disregard for new maintenance trends have forced these companies toward reactive maintenance, which is counterproductive to long-term plant operation. The study found that management commitment, maintenance planning, technical competence, digital technologies, and performance measurement are key determinants of maintenance maturity. Shifting from reactive to reliability-based proactive maintenance can improve equipment reliability and productivity, reduce costs, and enhance long-term competitiveness.