Case Studies and Client Successes
Improved Reliability through TPM
Despite three successful years of lean maintenance and achieving great outcomes (process-efficiency improvements, cost reductions) continued equipment failures kept them from meeting production targets.
Coming soon…
Our team is working on some exciting case studies from recent projects, and they’ll be available soon. Stay tuned!
Coming soon…
Our team is working on some exciting case studies from recent projects, and they’ll be available soon. Stay tuned!
What have we helped our clients achieve?
Aera Energy
- 40% Reduction in maintenance costs (1999-2002)
- 25% Increase in injection reliability
- 7% Increase in well on time reliability
Legget & Platt
- Maintenance budget reduction of USD 1M in the first 1.5 years
- 6% productivity improvement in our facility
- More than USD 740K reduction in operating cost (3 facilities)
- Fixed 3,178 previously unknown defects during ACW’s workshop
Shell Oman
- One formal RCA event netted a USD 1.5M savings
- Maintenance budget reduction of USD 3M in one year
- Increased Mean Time Between Failure (MTBF) on a compressor unit from 56 days to 210 days and still counting
Shell Europe
- Return on investment (ROI) is 10:1 over implementation costs
- More than 400% improvement in Mean Time Between Failure (MTBF)
- Estimates that the ROI from TPM has been ten-fold their cost of implementation
Kaiser Aluminum
- 22% Reduction in maintenance budget
- 17% Reduction in manufacturing costs
- 20% Reduction in storeroom inventory
- 40% Reduction in maintenance overtime
Energizer
- USD 1.5M reduction in maintenance labor cost
- USD 750K reduction in material costs
- 25% Improvement in planned work