Formerly known as TPM (total productive maintenance), Learning4Leaders has devised a tailored approach for any sector or industry. While traditional TPM methods prove effective in highly skilled, highly automated, and fast-moving manufacturing processes, the unique challenges posed by less automated and more manual tasks, as well as the distinction between factories with high and low care production facilities, necessitate a distinct approach that yields substantial business benefits.

The Learning4Leaders model understands the specific challenges associated with manual processes and less automated manufacturing within the FMCG sector, considering the varying needs of factories with high and low care production facilities. Through our Asset Care programme, we offer best practices for operations, quick changeover, and developing lubrication process maps and routines. By addressing these specific areas, we work towards increasing Overall Equipment Effectiveness (OEE), resulting in enhanced operational performance, and delivering tangible improvements to your business. Whether your factory operates with high care or low care production facilities, Learning4Leaders is committed to providing the highest standards of operational excellence.

Our client opted to replace their existing packing hall with a fully refurbished facility, equipped with state-of-the-art packing equipment. The previous packing hall required frequent engineering intervention, leading to substantial downtime during production shifts.

To address this, we trained Asset Care (AC) Operators to handle size changes, manage running issues, and conduct basic maintenance using ‘Clean-Inspect-Lubricate-Tighten’ routines. The AC Operators also completed planned maintenance tasks from the computerised system, developed best practices, and underwent a comprehensive operator training program.

Through our ‘Brand New Every Day’ initiative, Operators successfully completed our 5-module engineering familiarisation training, including hands-on exercises on the Learning4Leaders training rig. During the commissioning phase, the AC Operators collaborated effectively with the project and OEM engineers, developing maintenance routines to manage the new production equipment’s entire life cycle.

Additionally, the AC Operators received coaching in lean tools, such as Top Loss Model, SMED, 5S Workplace Organisation, and A3 problem-solving, empowering them to resolve challenging issues efficiently.

The disciplined approach to shiftly, daily, weekly, and monthly checks, along with line team inspections, significantly contributed to the success of the program. Under Learning4Leaders’ guidance, the client developed three skilled AC Operators capable of sustaining packing hall performance, leveraging data for continuous improvement, and effectively managing the new machinery’s life cycle.

This successful collaboration bridged the gap between operations and engineering teams, freeing maintenance engineers from basic tasks, enabling them to focus on more complex, preventative maintenance and engineering enhancements. The program’s impact on lean and line performance was critical, resulting in an efficient and high-performing production facility.