100
We specialize in implementing

Total Productive Maintenance

Focus on capital inten­sive indus­tries • finan­cially-driven approach • end-to-end solu­tions • high caliber inter­discipli­nary teams • broad project expe­rience • digitally enabled solu­tions • global reach

TPM as a key value driver

TPM adoption is still lagging in capital intensive industries...

The basic Total Productive Maintenance approach has been developed in Japan ~50 years ago in the automotive industry as part of the emerging lean manufacturing philosophy to maximize asset effectiveness with great success. Since then, many aspects of TPM have been improved as it has spread throughout the world and to other industries. As of today, however, the most capital intensive industries have still only partly adopted TPM, except for a few positive examples...

Automotive
TPM as standard practice
Engineering
Mostly adopted
Basic materials and chemicals
Partly adopted
Energy and mining
Lagging

Source: Estimates and perspectives from numerous seasoned industrial experts with at least 15 years experience in at least 5 countries and 3 industries regarding the world-wide adoption of TPM

...with signifi­cant im­prove­ment oppor­tuni­ties for CAPEX, OPEX, through­put and health & safety

The TPM asset management framework has significantly improved the quality of our investment decisions and substantially accelerated our capex implementation speed.

CEO - mining company

After implementing the OEE methodology (Overall Equipment Effectiveness), we have made step-change improvements in Opex, throughput and process stability. Systematic loss reduction has become a way of life at our site.

Site manager - steel company

We have increased the availability of key processes dramatically, while at the same time reducing the TRIFR substantially (total recordable injury frequency rate). Our maintenance team does way less firefighting today and focuses mainly on preventative tasks and equipment improvement, and our team has built substantial TPM skills.

Maintenance manager - chemicals company

TPM is an established philosophy and has gained traction over the past decade

  Evolution of TPM  

1970

Inception of approach

Invented in Japan in the automotive industry as part of the emerging lean manufacturing philosophy.

1990

Adoption in automotive

Spread by Japanese overseas subsidiaries and corresponding supplier development programs.

2010

Adoption across industries

Typically one of many elements of operational excellence, lean or six sigma programs.

Today

Strategic priority for many industries

TPM as one of the leading best-practice operations philosophies, especially in capital intensive businesses.

Our TPM services are based on a state-of-the-art modular and time-tested implementation playbook

Our services

We offer stand-alone TPM implementation programs or support larger footprint, operational excellence, lean or six sigma initiatives

1. Asset manage­ment frame­work

Compre­hensive Capex/ Opex manage­ment frame­work incl. stra­te­gic plan­ning, footprint, total cost of owner­ship, energy effi­ciency and environ­mental modules.

2. TPM full poten­tial diag­nostic

Quan­tification of finan­cial and opera­tional improve­ment potential with corres­ponding levers, impact on business plan and budgeting.

3. Imple­men­tation planning

Integrated Target Operating Model (TOM) with long-, mid- and short-term planning of TPM program, incl. PMO and team setup and progress-/ impact tracking.

4. Per­form­ance manage­ment

Capex/ Opex vs. plan, Capex imple­menta­tion effec­tive­ness, Total Cost of Ownership (TCO), Overall Equip­ment Effec­tive­ness (OEE), inci­dents/ activi­ties analy­ses, MTBF, MTTR etc.

5. Organi­zation and processes

Target organi­zation and sizing, roles and responsi­bilities, opti­mal support level setup, transi­tion planning and hiring, key TPM processes incl. mainte­nance supply chain and parts ware­housing.

6. Digi­tal en­able­ment

Optimization of existing mainte­nance software, new software selection and imple­men­tation, process sensor instal­lations, remote diag­nostics, auto­matic parts and people tracking, safety devices, mobile apps and ad­vanced ana­lytics tools.

7. Capa­bility buil­ding and coaching

Identifi­cation of required TPM and technical skill-sets, creation of training plans, targeted system­atic employee devel­opment.

8. Exe­cution and con­tractor manage­ment

Master project control for TPM program, new builds, enhance­ments and environ­mental require­ments, RFQs/ RFPs, con­trac­tor selec­tion and daily exe­cution manage­ment.

  Typical improvements 

20

Capex

30

Opex

15

Through­put

20

OEE

30

Downtime

60

MTBF

50

MTTR

30

Rework and waste

30

Spare parts inven­tory

15

Energy efficiency

50

Construction time

70

Meetings


Note: For general orientation and depending on client's level of TPM sophistication; individual potential to be estimated during diagnostic phase

Our people have im­ple­men­ted TPM success­fully across a wide range of industries

  Industries  

Steel and Aluminum

Germany • France • Spain

Chemicals

Germany • France • Benelux

Smelting

Germany • Scandinavia

Mining

Australia • Chile • Indonesia

Copper and Zinc

Germany • Kazakhstan

Energy

Germany • France • Poland

Field Force

UK • Germany

Oil and Gas

UK • Benelux

Automotive

UK • Germany • Brazil • Mexico

High Tech

Germany • Switzerland

Food and Beverage

UK • Germany

Pharma

Germany • Scandinavia

We are motivated by the measurable impact we achieve together with our clients

  Client feedback  

The TPM asset management framework has significantly improved the quality of our investment decisions and substantially accelerated our capex implementation speed.

CEO - mining company

We have increased the availability of key processes dramatically, while at the same time reducing the TRIFR substancially (total recordable injury frequency rate). Our maintenance team does way less firefighting today and focuses mainly on preventative tasks and equipment improvement.

Maintenance manager - chemicals company

After implementing the OEE methodology (Overall Equipment Effectiveness), we have made step-change improvements in Opex, throughput and process stability. Systematic loss reduction has become a way of life at our site.

Site manager - steel company

We have designed and implemented a tailor-made mobile app for our staff, the spare parts warehouse has been reorganized and an automatic tracking system has been introduced. This helps us to spend our time much more effectively. We have more efficient shift reviews and always know which shifts have been good/ bad and why.

Supervisor - energy company

  Approach  

Our sustainable TPM implementation approach comprises 4 phases
Phase 1


Diag­nos­tic

  • TPM start­ing point/ baseline
  • Gaps vs. best-practices
  • Key value drivers
  • Quan­ti­fied poten­tial
  • Im­pact on busi­ness plan
  • Review of budgets
Phase 2


Plan­ning

  • Tar­get oper­ating model
  • Im­ple­men­ta­tion master­plan
  • Work­stream defi­ni­tions
  • Teams and re­sources
  • Train­ing sched­ules
  • PMO and track­ing setup
Phase 3

Im­ple­men­ta­tion

  • Master pro­ject PMO ramp-up
  • Oper­ation­al adap­ta­tions
  • Orga­niza­tion­al tran­si­tion
  • Digi­tal en­able­ment
  • Skill- and capa­bility buil­ding
  • Short-inter­val controls
Phase 4

Cont. im­prove­ment

  • Per­form­ance man­age­ment
  • Oper­ation­al fine-tuning
  • Spe­cial­ized train­ing and coaching
  • PMO ramp-down
  • Hand­over to line manage­ment
  • Local CI orga­ni­za­tion setup
Partner­­­ships enable us to provide inte­grated state-of-the-art end-to-end TPM solu­tions

  Partnerships 

Busi­ness in­tel­li­gence

Microsoft PowerBI
Tableau
Qlik Sense
IBM Cognos
More...

CMMS and ERP

SAP S/4HANA PM
ABB Equipment Reliability
RA Fiix
Obzervr
More...

Asset man­age­ment

Aveva PI System
Oracle UMDM
GE Digital Asset PM
Isax ThingWorx
More...

Sen­sors and tracking

Process sensors
RFID solutions
Bar coding
LPS/ GPS tracking

Mobile appli­ca­tions

Google Android
Apple iOS
Native Apps
Progressive Web Apps

Engi­neer­ing

Global turnkey providers
Local turnkey providers
Global process experts
Proprietary expert network

High caliber interdisciplinary teams

  Our teams  

People

  • Individual backgrounds
    Our people have held senior positions in operations for at least 10 years and worked at leading consulting firms and world-class corporations.
  • Team composition
    Our unique blend of individuals covers all aspects and required skill-sets for a successful and sustainable TPM implementation: from asset lifecycle strategy to capex planning to equipment adaptations to organizational design to shop-floor coaching to IT-implementation.
  • Impact-orientation
    Each individual has worked in multiple countries in many different client situations with varied levels of TPM sophistication, and has driven corporate value in some of the most challenging environments.
  • Diversity
    We represent true diversity and offer highly complementary skill-sets, speaking all of the world’s main languages.
  • Round the clock staffing
    Through a mix of on-site and cross-continent remote-work, we have case teams 24/7 on any given engagement, shrinking overall execution times substantially.

How we work

  • Top priority: measurable and sustainable business performance impact
  • Stand-alone TPM implemen­tation program or part of larger footprint, operational excellence, lean or six sigma initiative
  • Full asset lifecycle perspective, integrating strategic aspirations and shop floor reality
  • Objective situation assessment and financial impact quantification
  • Data-driven insight generation and fact-based recommendations
  • Involvement of all levels of the organization
  • Strong implementation focus with go-and-see mentality
  • Attention to detail

Get to know our impact

Contact

We operate world-wide at our client's sites and prefer an initial contact by e-mail, including a short description of your TPM aspirations, locations, timeline and who has referred you to us. The relevant partner will contact you shortly.