Success Stories
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.
30-day PM Optimization
A well-known food manufacturer was facing operational challenges due to frequent unplanned downtime across all of their production lines. The manufacturer was aware that they were operating in reactive mode and were ready to change for the better.
Expedited Opererator Training
Employee turnover can impact companies in several negative ways, from loss of experienced talent and increased hiring costs to safety risks, compromised equipment reliability, and higher levels of rework and scrap.
Certification of Maintenance Planners
Following the impact of COVID-19, and influence of other factors, this mining company disbanded their Planning team. This resulted in the loss of experienced planners, vast amounts of tribal knowledge, and dip in process performance, reduced job plan quality and standardization.
Improving Production Capacity to meet Growing Sales
A client in the dietary supplements industry experienced a significant spike in sales and product demand, which exposed underlying capacity issues in their production process.
5-Day PM Optimization
Concerned that their PM strategy for a key physical asset was not delivering the necessary reliability, uptime, and product throughput, this adhesive tape manufacturer decided to act.
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