Through a well planned, multi-day Rapid Improvement Event, an effective Total
Productive Maintenance excellence strategy can help transform your company culture
into a world-class provider of reliable materials and services. MMTC can enable companies
to see and eliminate the hidden waste in their current operating and maintenance processes
by providing proven solutions for rapid improvement. TPM and planned maintenance activities,
when properly applied, enable companies to seize the opportunity to save time and money.
MMTC shows clients how to transform the traditional view of maintenance as a
"cost burden" into a LEAN "customer and cost focused" service provider. The
culture thus transforms its focus to long term performance improvement by maximizing
the performance of current technologies. This strategy can eliminate the need for costly
capital expenditures and allow greater flexibility to grow the business.
What Can TPM Do For You?
What if your organization could improve availability, performance, efficiency
and quality of just one machine?
| Current State |
Future State (w/ TPM) |
| Availability = 85% |
Availability = 90% |
| Performance Efficiency = 86% |
Performance Efficiency = 91% |
| Quality Rate = 94% |
Quality Rate = 99% |
OEE formula:
85% x 86% x 94% = 69% |
OEE formula:
90% x 91% x 99% = 81% |
| At 69% you produced 1,380 good parts (per week) with a profit of $2
per piece = EBIT for 50 weeks of $138,000 |
At 81% you can produce 1,703 good parts (per week) so your EBIT =
$170,000 using the same labor and piece of equipment |
Increased run time of good parts = increased EBIT of $32,200 from one machine.
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Bottom Line Facts
Although many organizations differ in their manufacturing processes, the typical approach
to maintenance remains an after-thought that is common in 66% of U.S. manufacturing firms.
- 180 million in annual lost revenue is directly
attributed to poor maintenance practices in U.S. manufacturing firms
- Re-establishing your maintenance
approach from a "cost-burden-failure" to a "cost-savings-success" typically will gain a minimum
of 6 to 1 payback
- Machines that are maintained proactively
generally consume 5% to 10% less energy
- Simple autonomous (operator based)
TLC (Tighten-Lubricate-Clean) generally eliminate 50% to 70% of unplanned stoppages
- Inadequate maintenance practices
typically waste 20% to 50% of spare part budgets unnecessarily
- Organizations that operate with traditional
"run till failure" methods, typically waste over 30% of every dollar spent on maintenance repairs
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