Process Improvement

• Waste Reduction
• Reduced Cost
• Increased Capacity and Profit
• Other Significant, Documented Results

Reduced soap waste by 96%

A major soap manufacturer reduced waste by 96% on one line by applying TPM Principles and using One-Point lessons.

38% decrease in cost per coil                                                                           An epoxy line at a Fortune 500 company applied TPM Principles and teamwork to achieve the following results...

• Decreased scrap by $95,000 annually
• Decreased cost/coil by 38%, increasing profits proportionally
• Labor & overhead reductions surpassed first year objectives by almost $550,000
• OEE at 85% (World Class!)

Increased Capacity by 88% and Profit by $19 Million

A major automotive trim plant used TPM and process improvement teams to achieve the following results:

• Equipment up time approaching 95%
• Parts capacity increased from 800K/year to 1.5 million/year, in two years

• Paint line profits increased by $19 million in three years

Other Significant, Documented Results

• Engine Plant - Demonstrated a 35 to 0.8 scrap rate reduction and a 45% increase in overall efficiencies

• European Plastic Injection Molding - Reduced costs to generate $520,600 in annual savings

• Liquid Packaging Lines - Enjoyed a 600% reduction in changeover and recovery time

• Paint Facility - Achieved a $95,000 decrease in scrap and $547,000 in direct overhead savings while doubling production volume

• Detergent Packaging Lines - Made step-change to a 40% improvement in Overall Equipment Effectiveness (OEE)

• Case Palletizer - Improved to effect a 25% increase in capacity

• Liquid Perfume Process - Achieved a 625% reduction in changeover and recovery time

• Air Compressor - Improved efficiency to net $110,000 savings in electricity and $250,000 in capital cost avoidance