A growing FMCG company, approached us to improve costs and ensure profit. In March-December 2021, we set a goal to implement an Asset Care (AM and PM) program on a model line and train internal resources to ensure line sustainability and horizontal expansion throughout the plant.
Baseline situation: lack of a plant management policy
Our client had a poor performance in terms of line availability, with a strong negative effect on the OEE and OTIF of the products and consequent customer complaints domestically and internationally. In addition, there was a lack of failure prevention culture and plant management policy.
Known problems: resistance to change and lack of knowledge of TPM/AM&PM methodologies.
The problems were mainly caused by the lack of knowledge of TPM/AM&PM methodologies and resistance to change of the senior department leader. The client chose us because of our references in the industry, sponsorship of one of the large distributors affected by the problem of late deliveries, and the general manager’s previous employment in another multinational company.
Implementation of the Asset Care program
We worked with our client to align strategic goals with key activities and programs, and implemented the Asset Care program to improve line efficiency and support maintenance activities. In addition, we introduced CMMS to manage maintenance activities.
Results: 30% reduction in maintenance costs and 8:1 ROI in 6 months
Our work resulted in a 30% reduction in maintenance costs and an 8:1 ROI in just 6 months. We also trained internal staff to ensure the sustainability of the Asset Care program on the model line and horizontal expansion throughout the plant.
Conclusions
Through our Asset Care program and our work with the team, the company was able to improve line availability, OEE and OTIF of products, reduce maintenance costs, and ensure profit. Our work has also created a culture of failure prevention and enabled them to better manage plants, ensuring customer satisfaction and company growth.