Culture of effectiveness and reliability
Total Productive Maintenance Consulting
Effectiveness and reliability start where production and maintenance stop working in silos
When equipment becomes unreliable, production pushes for output, maintenance reacts to failures, and both teams end up managing consequences instead of preventing them. The friction builds in downtime, in costs, and in the daily tension between two functions that should work as one.
We reframe this relationship through our TPM Consulting, embedding predictive and planned approaches into daily routine, so maintenance becomes what it’s designed to be: a support function that keeps production running, not a firefighting crew called in after the damage is done.
When that shift holds, downtime drops, and production and maintenance stop pulling against each other. That’s a culture of effectiveness and reliability built on prevention, not recovery.
Traditional Approach
Lean Approach
Traditional Approach
Repair when broken
Lean Approach
Prevent issues upstream
Traditional Approach
Focus on equipment availability
Lean Approach
Focus on full equipment effectiveness
Traditional Approach
Barriers between production and maintenance
Lean Approach
Collaborative maintenance
Our Solutions
We bring a full range of capabilities to help you upgrade your maintenance system. Our team of industrial maintenance experts implements a structured, precise, and customized approach. This allows us to quickly define a customized strategy for each customer. By considering our customers’ constraints and concerns, we can provide the best advice to move towards operational excellence in industrial maintenance.
- Increase Overall Equipment Effectiveness – OEE – by following a structured approach to eliminate failures.
- Develop problem-solving capabilities to identify and eliminate root causes effectively.
- Develop and deliver planned maintenance plans that improve equipment reliability.
- Maintain a cost-effective spare parts stock level and ensure the desired mean time to repair.
- Research and develop new technology to help monitor the equipment and improve performance.
- Train production operators to perform basic maintenance tasks such as cleaning, inspection, and lubrication.
- Ensure that operators can detect failures when they occur, ensuring rapid response and greater equipment reliability.
- Free maintenance teams to perform technical activities with greater added value (technical improvements, advanced prevention activities, planned maintenance, predictive analysis, structured failure analysis).
- Develop and implement a long-term training plan/academy for all operators.
- Guarantee that the lessons learned and technical knowledge gained are passed on between team members.
- Ensure proper implementation of new equipment on site.
- Reduce the lifecycle cost of equipment by working in the design phase to prevent problems with FMEA.
Talk to an Expert
Get in touch with us and share your business needs to get a tailored consulting or training approach
Impact
8 to 15%
Average overall equipment effectiveness increase
10 to 30%
Average maintenance costs reduction
20 to 35%
Average material losses reduction
Insights
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Every industry faces different obstacles
Kaizen Institute works directly with the client teams, with a “Hands On” and “Learning by Doing” approach
Kaizen Institute works directly with the client teams, with a “Hands On” and “Learning by Doing” approach