For a firm which had problems with its manufacturing reliability and in which we provided diagnostic analyses and recommendations to solve them…
Key Business Issues
- Poor throughput and reliability
- Frequent machine stoppages
- Equipment breakdowns
- High maintenance costs
- Chronic quality issues and scrap losses
- Environmental and safety defects
- Inadequate skills
Services Provided
- Baseline Assessment and Review
- TPM Strategy Development
- TPM Program and Organization Design
- Training and Coaching
- Progress Reviews and Feedback
Solution Components
- TPM Goals and Masterplan
- Organization design and structure
- TPM Pillars Training and workshops
- Small Team loss elimination activities
- Integrated review and kaizen system
- Computerized Asset Management and Maintenance System
Business Results
- Achieved >85% Reliability; increase throughput without additional capital or people
- Reduced stoppages by 30%
- Eliminated breakdowns by 50%
- Cut maintenance costs by 20%
- Reduced scraps and product defects
