The True Power of TPM for successful companies.docx

TPM KMI

1. The True Power of TPM: Our Success Case at BGC
Ronrapee Leelawong
Director, People Development
June 30, 2021
Recently I had a chance to update our executives and managers about progress of our BGC Excellence Management Program (BGC-X), which has been implemented for
almost 18 months, with mixes of setbacks and successes. 
Apart from typical result and progress reports of each module and activity, I want to stress one of our success stories from one of our plants that implements TPM. The
story I shared is about an AM (Autonomous Maintenance) activity at a packing line – a pallet strapping machine. This area has been doing AM activity since February 2021. 
In the beginning, our efforts, reactions and initial results are very typical as any other CI activity everywhere. The area and its machines are not in a good shape, standard
(and understanding) of the word ‘cleaned’ is low and people are there just to push stand and stop, … that’s it noting else, when there was a problem, just call maintenance
guy.
On my first visit in February, even though they have tried their best to prepare the area and the machine, it was easy for me still to find dirt, debris, oil-strains, etc. on the
floor, and point-out easy improvement opportunities that were they wherever I look at. I remember that on that visit, the operator (not skilled, as the job requirement of
that area is bare minimum, no specific skill, education, experiences needed) listened to me with blank eyes with most of my words just flew thru his ears. He only nodded to
be polite (and in part, perhaps he was scared as well, haha.) These are all typical of a normal company, normal shop-floor, normal operations.
But we need an EXCELLENCE one... we need to improve this!
As we continued to press on, twice a month my team visited – giving lecture, coaching on the shop floor, working with the operators, even performing some mundane tasks
to show how they should be done properly. We introduced essential tools and practices of AM – tagging, writing OPL (One-Point-Lesson), cleaning for inspection, finding
Hard-To-Access (HTA) areas / Source-of-Contaminations (SOC), etc.

2. Last week, I went back there again to perform top management audit for AM step 2. After 5 months of consistent activity and grinding practices.
Now, anyone can see a huge improvement!
The area and its machine are crisp, cleaned, and in ‘like-new’ condition. I am sure they must try their best to ‘polish’ the area before I visit… same as every time there is a
top management visit. (But remember that before my first visit in February. they also did that as well,… with much lesser success.)
A lot of modification and improvements were in place to enhance how they take care of the machine day-to-day. The machine even has some better functions or tweaks
than the original one, I am pretty sure.
More than the physical improvement, what impressed me most it the people’s ‘SPRIRIT!’ How things have changed in term of the operators who are responsible for this
machine.
Whom I met on my latest visit last week it a totally different person from whom I met 5 months ago.
His eyes were sparkling, bright and full of live.
His voice was clear and echoing a feel of confident. 
His face is full of smiles, ...proudly smiles.

3. Every two or three sentences as he presented, he urged me to go to see the 'real improvements' he has made on his machines (I had to stop him time and again to tell him
that we would finish his information board presentation first before we go to see the real things.) 
Whenever I congratulated him on his successes or his modifications and tried to convinced him to go further, to improve continually to the next step, or to suggest him
some good ideas that I have seen from my past, he will quickly responded to me like “Yes, sir, I’ve already thought about that, and my idea (or my next move) is,… blah
blah,” and he continued on and on with his ideas about how to make the next level improvement, ...to make his machine better, and better. 
And, please, be reminded that this operator is at the bottom level of the organization (no offense, but this is life, isn't it?) He has no specialties (as the job does not require,
by design) and minimum education background, with almost minimum benefits the company provides him in exchange of his service.
Yet,… yet he possesses great mindset, competence and ability to improve his machines (how he works and takes care of his machines) above and way beyond his job level,
or his title requires. His CI mindset is better than some of our prestigious, -expensive- improvement engineers, or skilled supervisors! (again, sorry to say this, and no
offense,... this' life, isn't it?)
Many of our executives and I are very impressed.
How people have changed and improved is always impressed me. Always. Every time. And forever. Even though I have seen this happens again and again in a proper and
success TPM program everywhere. 
This align with my mantra of 'how people have changed and improved' is always my first priority.
IMHO, I think how people have changed and improved is the most important and biggest benefit of TPM Program. TPM program is so powerful because it can change
people, …especially people on the shop-floor (sadly, who maybe seen by some as having the least potential to grow ...and glow.)
And I think I have fully supported and have been a dedicate fellow of TPM because of this - how it can changed people – behaviors, mindsets and skillsets, bits by bits
overtime, every time we practice, continually, and infinitely!
As one of the basic principles of TPM I always tell everybody who is new to TPM:
“TPM changes (improves) people, so that people then start and continue to change (better take care and improve) their machines.”
(And thus we are not focusing on the machines in the first place or as our first priority… as some may misunderstand about TPM.)

4. Case Studies of Successful TPM Implementation
TPM or Total Productive Maintenance is a maintenance strategy that aims to increase the efficiency and effectiveness of
production by involving all employees. Many companies have successfully implemented TPM and achieved significant
benefits. Here are 50 case studies of successful TPM implementation, compiled from publicly available information. These case
studies demonstrate the benefits of TPM implementation across various industries. ( https://www.maintwiz.com/tpm-case-
studies/)
S.
No.
Company Industry TPM Goals Benefits
1Toyota Automotive
To reduce equipment
downtime, improve
productivity, and reduce
costs
Reduced equipment downtime by 50%, increased productivity by 20%, and reduced
costs by 15%
2Nestle
Food and
Beverage
To improve Overall
Equipment Effectiveness
(OEE)
Increased OEE from 65% to 85%, reduced maintenance costs by 30%, and improved
product quality
3PepsiCo Food and To reduce downtime, Reduced downtime by 30%, increased equipment reliability by 25%, and reduced

5. S.
No.
Company Industry TPM Goals Benefits
Beverage
improve equipment
reliability, and reduce costs
maintenance costs by 20%
4Honda Automotive
To improve quality, reduce
costs, and increase
productivity
Reduced maintenance costs by 40%, increased productivity by 25%, and improved
product quality
5Procter & Gamble
Consumer
Goods
To reduce equipment
downtime, improve quality,
and reduce costs
Reduced equipment downtime by 30%, improved product quality, and reduced
maintenance costs by 20%
6Unilever
Consumer
Goods
To improve equipment
efficiency and reliability
Reduced downtime by 50%, increased efficiency by 20%, and improved product quality
7Boeing Aerospace
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
8Samsung Electronics To improve equipment Reduced equipment downtime by 40%, increased efficiency by 30%, and reduced

6. S.
No.
Company Industry TPM Goals Benefits
efficiency and reduce costsmaintenance costs by 20%
9Coca-Cola
Food and
Beverage
To reduce downtime,
improve equipment
efficiency, and reduce costs
Reduced downtime by 30%, increased equipment efficiency by 20%, and reduced
maintenance costs by 15%
10Ford Automotive
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
11General ElectricEnergy
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%
12BMW Automotive
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 20%, increased equipment reliability, and improved
safety
13Intel Technology
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 30%, increased efficiency by 25%, and reduced
maintenance costs by 15%

7. S.
No.
Company Industry TPM Goals Benefits
14Daimler AG Automotive
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
153M Manufacturing
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 20%, increased equipment reliability, and improved
safety
16Siemens Energy
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 25%, increased efficiency by 20%, and reduced
maintenance costs by 15%
17
Hindustan
Unilever Limited
Consumer
Goods
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 30%, increased efficiency by 25%, and reduced
maintenance costs by 20%
18Sony Electronics
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 25%, increased efficiency by 20%, and reduced
maintenance costs by 15%
19ABB Manufacturing
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety

8. S.
No.
Company Industry TPM Goals Benefits
20Nissan Automotive
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
59Google Technology
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 25%, increased efficiency by 20%, and reduced
maintenance costs by 15%
22Volvo Automotive
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
23General MotorsAutomotive
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
24Bayer Pharmaceuticals
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%
25
Whirlpool
Corporation
Appliances
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%

9. S.
No.
Company Industry TPM Goals Benefits
56Chevron Oil and Gas
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
27Bridgestone Tires
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
28Caterpillar Construction
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
29ExxonMobil Oil and Gas
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%
30United AirlinesAviation
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
69Volkswagen Automobile
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%

10. S.
No.
Company Industry TPM Goals Benefits
33
Hindustan
Petroleum
Corporation
Limited
Oil and Gas
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
34
Siemens Gamesa
Renewable Energy
Energy
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%
35GSK Pharmaceuticals
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
36Coca-Cola Beverages
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 25%, increased efficiency by 20%, and reduced
maintenance costs by 15%
37Dow Chemical Chemicals
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
38DuPont Chemicals To improve equipment Reduced maintenance costs by 25%, increased equipment reliability, and improved

11. S.
No.
Company Industry TPM Goals Benefits
reliability and reduce costssafety
39
Exelon
Corporation
Energy
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%
40Lockheed MartinAerospace
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
41Monsanto Food
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 25%, increased efficiency by 20%, and reduced
maintenance costs by 15%
42NASA Aerospace
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
43Walmart Retail
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 25%, increased efficiency by 20%, and reduced
maintenance costs by 15%

12. S.
No.
Company Industry TPM Goals Benefits
44Pfizer Pharmaceuticals
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%
45ABB Electronics
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
46Amazon E-commerce
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%
47Unilever
Consumer
Goods
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 30%, increased equipment reliability, and improved
safety
48Valero EnergyOil and Gas
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety
51Nucor Steel
To improve equipment
reliability and reduce costs
Reduced maintenance costs by 25%, increased equipment reliability, and improved
safety

13. S.
No.
Company Industry TPM Goals Benefits
52Shell Oil and Gas
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 25%, increased efficiency by 20%, and reduced
maintenance costs by 15%
53Tesla Automobile
To improve equipment
efficiency and reduce costs
Reduced equipment downtime by 20%, increased efficiency by 15%, and reduced
maintenance costs by 10%