For some years now (more
than 40) I have been in very close contact with the
industrial maintenance activity.
I have understood that we should always
look for new formulas to make it simpler better and more efficient. It was until I
started looking at TPM that I felt the real "Click".
The involvement of the customers is
Very important, perhaps
that is the key to success in all the activities.
The companies I have been working with are experiencing impressive set up time
reductions, machines that are doing what they never did, savings in the processes and
improvement in the final product.
Mr. Dyer from Productivity Inc. is proud as well of the results achieved by some of
the companies that have implemented TPM. In an interview recently published on the
Internet he said: "Copeland Industries, for example, implemented a
very effective TPM program. Since that time, the company has recorded a 57 percent improvement in manufacturing
cycle time, scrap and rework costs have declined by 72 percent, manufacturing costs are
down 60 percent, plant operating costs declined by $2 million in just 18 months and total
downtime for maintenance was at an astounding 1.9 percent,.."
Some companies with old machines were having poor performances from them. I have the
case of a pipe bender that had never been able to bend schedule 80 steel pipe in short
radius and had an unacceptable 30% downtime. After the TPM effort, with new seals, improved clamps and fine tunings in the
hydraulic system, it does bend it...
and the downtime is now less than 0.5%
Mr. Floyd an important executive from Exxon said one of the most impressive measures
in his mind is Exxons process capability index, which is currently 1.75 up from 0.61
That, coupled with a reduction in Exxons maintenance costs to
1.9 percent of replacement costs, has illustrated how
effective TPM can be in a process industry.
Examples can be counted by the hundreds, but the real question is:
Are you getting the good results
that you expected?
If your answer is no, or you have not determined yet what practices should be
adopted, we invite you to get some external help.
Do you Want to get the
Enrique Mora has been successfully involved in the design and implementation
of this kind of programs for more than 30 years.
Mora Consulting can visit your plant and tell you if TPM is for you,
what can be realistic to expect, and how long it may take. Do not expect any outrageous
Also for free you can submit all your
questions directly to Enrique Mora... through
him, click here!
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