Client

Manufacturer of high value products for mining

Scope

Introduce Total Productive Maintenance to lift line performance in order to consolidate European operations. A unique opportunity to insource from Asia.

Diagnostic

  • Full review of maintenance practices and performance
  • Identify bottlenecks on 3 key production lines

Actions

  • Introduce OEE (manual data collection and calc) on identified bottlenecks with uptime on secondaries and tertiaries
  • Re-allocation of Planned Maintenance activities to drive operator maintenance
  • Introduce line-side stock for key parts and consumables
  • Early Equipment Management introduced for next generation equipment ready for delivery in 6 month horizon
  • Quick Change Over activities on line start-ups, tool changes and product changeovers

Results

  • Shift requirements reduced from 5 to 4
  • 4 products in-sourced from Asia improving quality and unit cost
  • TPM programme deployed across the group

Our TPM programme has helped to reduce maintenance and operating costs for clients by up to 25 percent.

GENEO’s approach helps clients to reduce their maintenance burden through our rationalisation programme and turn planned maintenance activities into effective work standards for use in the workplace.

Trialled and perfected transformation method

GENEO has developed a unique deployment model to accelerate your Lean transformation. Contact us to understand how GENEO can help boost your Lean transformation.

Continual success stories

GENEO continues to grow its business based on the great results we achieve with our clients. No engagement is ever the same, each one presenting a unique set of challenges for our team, challenges that we heartily accept and overcome jointly with our clients.

Leadership training

We are training leaders to make a difference by leading Lean with the appropriate behaviours to make a significant difference to their Continuous Improvement culture. It’s all about people and we are all about people.
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