GRUPAS TPM – Total Productive Maintenance Model
In production facilities, breakdowns, unplanned downtime, scrap and hidden losses are the greatest obstacles to capacity and profitability. The GRUPAS TPM – Total Productive Maintenance Model is an end-to-end transformation program designed to make these losses measurable and eliminate them systematically. The program advances in three stages: Initial Meeting, Preparation Phase and Development Phase. A concrete roadmap is created by establishing the OEE structure at the pilot plant, together with loss–cost analysis, ROI calculation and an Improvement Master Plan for roll-out across the entire facility.
The development phase is built on six core pillars: Autonomous Maintenance, Focused Improvements, Professional Maintenance Management, Training & Skill Development, Daily Management System and Visual Management System. Through modules such as OEE, Kaizen, 5S, SMED, VSM, Kanban, A3 and problem-solving techniques, shop-floor and management teams are developed together.
Business Results Achieved with TPM
- Capacity increase and a continuous rise in the OEE value
- Significant reduction in breakdowns and elimination of unplanned downtime
- Higher quality, with quality deviations and scrap/reject rates minimized
- Increased profitability and measurable ROI thanks to the costing of losses
- Higher operator competence, greater employee productivity and engagement
- An effective, preventive and planned maintenance system; improved maintenance quality through MTTR/MTBF tracking
- Improved OHS and environmental performance, moving closer to the zero-accident target
- Gains made sustainable through standards, visual management and daily management discipline
Who Is It For?
Industrial manufacturing organizations; plant and production managers, maintenance managers, quality and continuous improvement teams, and senior management teams targeting operational excellence. The program is designed to start at a pilot plant and spread across the entire organization through parallel workstreams over approximately 24 months.
With our People | Process | Technology approach, we are ready for enthusiastic collaborations.
