Real TPM Results
Operational transformation with measurable impact and proven return
We present the results of three plants audited on two occasions by JIPM of Japan.
These three examples were randomly selected from the 37 plants that have been audited by the Japan Institute of Plant Maintenance for the International TPM Awards, in processes where we had the honor of accompanying them as consultants.
In all cases, we applied the original TPM methodology rigorously, adapting it to each client's priorities and urgencies, but without compromising its integrity.
The information presented is authentic and represents a real competitive advantage for the companies that trusted TPM and JES as their consulting firm. In respect to confidentiality and the strategic value of these results, the names of the plants and organizations are not disclosed.
Indicator |
Year 1 TPM |
TPM Excellence Award |
Main Benefits | |
|---|---|---|---|---|
| P | Average monthly breakdowns | 1350 | 85 | • Overtime elimination • 30% maintenance cost reduction • Avoided purchase of 2 machines |
| OEE | 48% | 70% | • 3 machines shut down • 1 work shift eliminated • Higher return on invested capital |
|
| Q | Average monthly customer complaints | 10 | 2 | • Greater customer trust • Less production line stress • Increased supplier involvement |
| Monthly waste - Defects (pieces) | 12,960 | 6000 | • 54% rework reduction • Unit cost reduction • Improved available capacity and productivity |
|
| Monthly production waste | 55,280 | 12,100 | • $$$ savings | |
| Destroyed product/month | $24,280 | $400 | • Over quarter million dollars savings! | |
| C | kWh consumption per piece | 0.29 | 0.16 | • 45% electricity reduction/unit |
| Annual warehouse cost | $8,230,000 | $4,200,000 | • This saving alone paid for all 7 years of consulting! | |
| Maintenance cost per piece | 0.011 | 0.008 | • 27% maintenance cost reduction | |
| D | Service Level | 78% | 100% | • Recurring sales growth • Customer loyalty and retention • Elimination of penalties and non-compliance costs |
| S | Accidents | 18 | 0 | • Elimination of compensation, insurance premiums and downtime losses • Mature safety culture • Prevention culture |
| M | One Point Lessons | 75 | 8,000 | • Total participation • Prevention of recurring problems • Reduction of human error losses |
| Focused Improvement Cases | 0 | 1558 | • Alignment of improvement cases with top management strategy • Elimination of chronic losses • Hidden capacity release |
|
| TPM Training (hours/man/month) | 1.8 | 8 | • Talent development and motivation • More skilled and flexible workforce • Human error elimination |
|
Indicator |
Year 1 TPM |
TPM Excellence Award |
Main Benefits | |
|---|---|---|---|---|
| P | Average monthly breakdowns | 1,911 | 375 | • 80% reduction • +384 additional production hours |
| OEE | 50% | 82% | • 64% increase • CAPEX project cancelled |
|
| Q | Customer Complaints (ppm) | 44 | 10 | • 88% reduction • Market share increase |
| Defective parts (PPM) | 4,100 | 496 | • 87.9% reduction • Productivity increase |
|
| Monthly production waste | $150,000 | $57,000 | • 62% reduction • Product cost reduction |
|
| Destroyed finished product (monthly) | $17,000 | $2,100 | • 88% reduction • $178,000 annual savings |
|
| C | Service Level | 88% | 99% | • 12.5% improvement |
| Accidents per year | 8 | 0 | • Improved work environment and company trust | |
| One Point Lessons | 437 | 64,896 | • 148 times increase! | |
| Focused Improvement Cases | 4 | 3,306 | • Improved OEE and reduced major loss costs. | |
| TPM Training (h/month/person) | 0.03 | 9.3 | • Systematic development of personnel skills. | |
Indicator |
Year 1 TPM |
TPM Excellence Award |
Main Benefits | |
|---|---|---|---|---|
| P | Tons per month per man | 15 | 21.2 | 40% increase |
| OEE | 62% | 84% | 22% increase | |
| Annual Breakdowns | 3,384 | 120 | 96% reduction | |
| Q | Annual Customer Complaints | 29 | 4 | 86% reduction |
| Quality Failures (Tons/year) | 24,672 | 1 | Absolute trust. Loyalty and repeat purchase. Strengthened reputation. |
|
| C | Energy Consumption (kWh/Ton) | 203.60 | 174.40 | 15% energy consumption reduction. |
| Water Consumption (m³/Ton) | 3.13 | 1.77 | 43% reduction | |
| Fuel (L/Ton) | 35.69 | 13.58 | 62% reduction | |
| D | Lead Time (hrs) | 10.00 | 6.50 | 35% reduction |
| OTIF | 54% | 97% | 43% increase | |
| S | Accidents | 40 | 26 | 45% reduction Pending subject. |
| Emissions (Kg CO₂/Ton) | 116.60 | 40.40 | 65% reduction | |
| M | Employee Turnover | 3.89% | 1.48% | 62% reduction |