TPM Consulting

Measure Productivity. Minimize Downtime. Maximize Efficiency. 🚀

Total Productive Maintenance (TPM) – Boost Productivity & OEE

In continuous batch process industries, unplanned downtime, low machine efficiency, and inconsistent output silently eat into profits. Many industries face challenges like

High Operating Costs – Labour, utilities, and maintenance costs are higher due to inefficiencies.

Rising Rejection Rates – Poor machine performance can triple operational costs due to scrap and rework.

Excessive Capital Investment – Buying more machines without improving existing ones locks up capital unnecessarily.

Lack of Data-Driven Decisions – Critical issues remain hidden, and management relies on guesswork.

High Labour Costs – Teams spend excessive time fixing recurring problems instead of working efficiently.

Unknown Losses – Many are unaware of the 16 major losses impacting productivity.

Sales Challenges – Competitors often sell at better prices while maintaining higher profitability.

The desire is clear: optimize machines, reduce costs, improve quality, and make smarter, data-driven decisions that directly impact profitability.

Live Training Examples

TPM – Transforming Productivity in Continuous Batch Industries

TPM is a holistic approach to maintenance that ensures machines, processes, and teams work efficiently, safely, and reliably.

The 8 TPM Pillars

Step 1

Autonomous Maintenance

Operators maintain and inspect machines daily to catch issues early.

Step 2

Planned Maintenance

Proactive schedules reduce unplanned downtime.

Step 3

Quality Maintenance

Prevent defects by ensuring optimal machine performance.

Step 4

Focused Improvement

Teams systematically eliminate productivity losses.

Step 5

Early Equipment Management

Design and install machines for long-term reliability.

Step 6

Training & Education

Build skills for operators and maintenance teams to sustain TPM.

Step 7

Safety, Health & Environment

Streamline administrative processes to prevent bottlenecks.

Step 8

TPM in Office/Support Functions

Streamline administrative processes to prevent bottlenecks.

Outcome: Higher OEE, safer operations, improved productivity, and a workplace that runs like a well-oiled machine.

Measuring Productivity with OEE

OEE (Overall Equipment Effectiveness) is the key metric to measure machine and process efficiency. It evaluates:

Availability: How often machines are running versus downtime.
Performance: Whether machines operate at optimal speed.
Quality: How much output meets standards without rework or rejection.

By improving OEE, companies can increase production without additional machines, reduce costs, and enhance profitability. TPM focuses on identifying losses, optimizing efficiency, and sustaining improvements to achieve measurable results.

Common Pain Points Without TPM

Machines running below optimal performance

Frequent breakdowns affecting production schedules

High maintenance and operational costs

Unsafe work conditions and workplace hazards

Difficulty measuring productivity accurately

Inefficient workflows and frustrated teams

Industry-Specific Benefits for Continuous Process Industries

Total Productive Maintenance (TPM) drives continuous process improvement for industries where uninterrupted operations, efficiency, and quality are critical. Key benefits for continuous process industries include: