Back in 2011, our customer – an Asian dairy producer – faced a number of issues. Their KPI system was weak, claims rate from the market was higher than desired and equipment breakdowns were resulting in many internal quality defects. To address these quality issues, we started the Continuous Improvement Journey by implementing a 2-year Operational Cost Guarantee program. The results, which included an increase in Overall Equipment Efficiency (OEE) from 40% to 65%, were positive. The customer decided to expand the continuous improvement activities to the whole factory, and improve quality in all plant loss areas.
We expanded the existing Continuous Improvement activities into a full Total Productive Maintenance (TPM) approach. In short, this maintenance service means that everyone within the organisation, from top management to line workers, endeavours to maximise productivity.
The key principles when implementing TPM are:
The customer chose a 3-year implementation plan, which included education and training in quality management and safety.
The customer’s Overall Equipment Effectiveness increased from 65% by the end of 2013 (which in turn was an increase from 40% in 2011) to 78.53% in 2016. Claims from the market were reduced by 73.8% - from 4.2 to 1.1 parts per million (ppm) between 2013 and 2016. Internal failures – defects per 10’000 packages – decreased too: from 0.32 in 2013 to 0.13 in 2016.
The customer continues their TPM journey with our ongoing support.