In summary, this company has been able to reduce both customer complaints and regulatory complaints to zero. Also, they reduced in-process defects by 83 percent and reduced cost of quality by 46 percent.
Those are commendable figures that can’t and shouldn’t be easily discarded.
Better Overall Performance
One major advantage of TPM is that it takes some pressure off the maintenance team and allows them time to concentrate on more complicated (and more important) maintenance tasks. Eventually, this shift in the workflow improves overall productivity and performance of a food and beverage plant.
TPM is a systems-wide approach: From top to bottom, from boardroom to plant floor—everyone is involved. It encourages learning and improvement across an entire plant’s value chain. The quality management and focused improvement pillars help identify and quickly eliminate non-conformances in a methodical and structured manner.
By implementing TPM, companies will reduce safety risks and eliminate some common symptoms of disorderliness such as dirty or messy workstations, missing or wrongly placed tools that can constitute a trip hazard, and so on.
On top of that, since major food manufacturers must adhere to several FDA regulations such as current Good Manufacturing Practices that regulate equipment, methods, facilities, processes, and controls, TPM also helps staff detect and address issues proactively and make a facility better prepared for any regulatory audits.
Final Thoughts on TPM
Like most other lean tools, TPM is not a quick solution to all your company’s problems. It requires a systematic and thorough planning, employees that are open to change, and an organization with a lean culture.
As it often takes several years to fully implement and begin to see major results, a half-hearted approach to implementation will only drain your resources and won’t provide a high ROI.
But those that follow through and successfully adopt TPM could see benefits in their business operations, processes, and of course, their bottom line.
Christiansen is the founder and CEO at Limble CMMS. Reach him at firstname.lastname@example.org.