Successful Maintenance with Total Productive Maintenance (TPM)
Often maintenance is seen as a necessary but burdensome task. By the implementation of Total Productive Maintenance (TPM), potential savings along the entire value added chain can be found and maintenance can be optimized going forward. Essential for success is the inclusion of maintenance in the daily routine.
Maintenance as an integral part of daily routine
Maintenance is a significant cost factor for a company, and its efficiency directly affects productivity. Along with cost reduction measures, an increase in productivity and equipment availability are the focus of our maintenance projects. In order to successfully experience Total Productive Maintenance (TPM), its implementation must be oriented to your company’s culture and integrated into the company’s daily routine.
An important variable for Operational Excellence is maintenance. The success of Total Productive Maintenance (TPM)-Projects is dependent on employee acceptance. Therefore, we first classify maintenance measures; and after a detailed analysis, we and your employees jointly prepare solutions that directly address your company goals. Through our tailored TPM-Process, we stabilize your facilities going forward and optimally take full advantage of the improvement potential.
Typical Results of a Maintenance Program
- Stabilization of facilities and production
- Reduction of work stoppages
- Reduction of maintenance costs by up to 15%
- Reduction of variable production costs by up to 10%
- Reduction of scrap costs
- Optimization of lot sizes
Maintenance with Total Productive Maintenance (TPM) in Action
Through the implementation of a solid operating and maintenance system, we were able to significantly reduce maintenance costs; and at the same time, we substantially increased equipment availability for our client, an innovative energy producer.
Fuels used to produce energy and their aggressive exhaust gases caused high equipment deterioration. After a detailed analysis of maintenance measures, the main cost drivers were identified. Building on that information, different modules of Total Productive Maintenance (TPM) were introduced at the plant. Here, work scheduling and choice of the selection of maintenance measures were a priority.
In order to achieve cost effective operations and maintenance management, the TPM-Modules were adjusted to take into account the decentralization of the facilities and the low number of employees in the maintenance group. In total, a stabilization of the facilities and a reduction in the number of failures of 24% was achieved.