TPM
Total Productive Maintenance
Reduce your operation costs and improve your product quality with TPM
The ROI (Return on Investment) of a TPM (Total Productive Maintenance) implementation can vary depending on plant maturity, commitment level, and implementation approach, but based on industrial studies and real cases, we can establish solid reference ranges:
Metric |
Expected results
(4 to 6 years)
|
---|---|
Typical ROI | 300% to 800% |
Payback period | 36 to 48 months |
Reduction in unplanned stops | 40% to 80% |
OEE increase | +42% |
Maintenance cost reduction | -50% |
Accident reduction | 80% |
Quality defects reduction | 50% |
OTIF improvement | 50% |
Annual savings | $1,800,000 USD |
Breakdown reduction | -99% |
Customer complaints | -100% |
New projects budget compliance | 100% |
Product cost reduction | -30% |
Spare parts inventory reduction | -45% |
Raw materials inventory reduction | -40% |
Human error failures | -98% |
Water consumption reduction | -37% |
Metric |
Expected results
(4 to 6 years)
|
---|---|
Typical ROI | 700% |
Traffic accidents | -90% |
Maintenance cost | -40% |
Spare parts inventory cost reduction | -50% |
Fuel expense | -15% |
Breakdown reduction | -85% |
Maintenance plan compliance | 100% |
In an environment where every unproductive minute represents financial losses, not accurately diagnosing a plant's condition means assuming unnecessary risk.
Top executives need clear, actionable information with tangible impact. JES's team of experts helps detect hidden opportunities that translate into real productivity increases and significant cost reductions.
Our methodology compares current operations against world-class Japanese standards, identifying gaps that are limiting productive potential.
The result: a strategic roadmap defining concrete actions, proven methodologies, and impactful tools to optimize financial and operational performance.
TPM was born to improve equipment reliability, but today it's a comprehensive system that transforms the entire supply chain.
The 8 pillars of TPM allow structuring an operation based on effective communication, continuous improvement culture, and World Class production.
Many companies try to implement TPM; few manage to sustain it. The differentiator is committed senior management that sees excellence not as a goal but as a permanent standard.
With JES, implementation is holistic and human. We accompany the organization step by step, achieving failure reduction, waste elimination, and better financial indicators.
The JIPM awards represent one of the highest standards of operational excellence. But their true value lies in the preparation process, which pushes the organization to identify weaknesses, strengthen capabilities, and consolidate a culture of improvement.
At JES we have accompanied companies in obtaining Consistency, Special and World Class awards under the guidelines of the Japan Institute of Plant Maintenance, maximizing organizational learning and corporate prestige.
Fleet management represents an often underestimated cost center. With TPM methodology applied to vehicles, JES transforms this operational pain into a source of sustainable savings and greater safety.
Our approach covers primary, secondary and utility fleets, generating concrete results in accident reduction, efficient maintenance and logistics waste reduction.
The TPM philosophy has also proven effective in the agribusiness sector. JES has led implementations that optimize machinery use, improve field productivity, and professionalize agricultural management.
Contact us to learn about real success cases in the sector.
5S is not just a cleaning and organization tool. It's the first step toward a culture of operational discipline that facilitates problem detection and prevents waste from the ground up.
Its application across all areas improves safety, work environment, and prepares the ground for sustainable Lean and TPM.
JES specializes in applying Lean tools that maximize customer satisfaction through systematic reduction of operational losses (muda, muri, mura). When integrated with TPM, these tools create a robust platform for continuous improvement and sustained economic value generation.
JES's TPM model for supply chain seeks to maximize efficiency, reliability and continuous flow of materials, information, and products, eliminating losses across the entire logistics network.
We integrate all links with a management system that creates harmonized flow and better customer experience while dramatically improving financial indicators.
FROM PREVENTION TO PRODUCTIVITY, TPM IS INTEGRAL LOGISTICS.
We offer professional simultaneous and consecutive interpretation services Japanese-English-Spanish, specialized in TPM (audits, Health Checks, training and consulting).
Our team ensures every interaction with Japanese experts is precise, effective and contextually accurate.
To ensure continuity of progress, JES offers online consulting services that allow tracking activities, preparing audits or reviewing specific cases quickly, efficiently and economically.
Schedule directly with your consultant or contact us at: yuri@jesamerica.net
What TPM can do for you (6 minutes)
Introduction to TPM (1 hour) (Spanish)
Reduce your fleet costs and improve customer satisfaction!
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