Using Data to Unlock Excellence

The TPM Excellence programme leads to better use of data by developing capabilities to define notification triggers and rule based decision models to establish:

• Early warning systems — making Normal Conditions visible and defining prompt action when deviations occur.

• Troubleshooting algorithms — formalising root cause analysis and response methods at common trouble hotspots.

• Work standards — embedding compliance to best practices and ensuring a continuous feedback loop to refine methods.

Making it Happen

TPM Excellence starts with an honest assessment of how the organisation uses data against five categories of data use , These are:

1. Capture — Basic data collection to meet financial reporting needs.

2. Share — Performance data captured and shared, but not yet acted upon by those collecting it.

3. Prioritise — Data used to set improvement priorities and targets.

4. Analyse — Data leveraged to improve repairs, design, spare parts storage, tools, troubleshooting and problem detection.

5. Optimise — Data fully integrated to optimise processes and deliver step-out product and service performance.

The steps of the TPM Excellence programme each incorporate the development of capabilities to use data though practical projects that also deliver measurable gains.

Milestone 1 Detect and resolve abnormal conditions

• Data used to highlight critical asset conditions

• Measurable gains include reduced lost time and lower spares costs.

Milestone 2 Simplify complex routines

• Data used to define "Normal Condition" standards and highlight deviations.

• Measurable gains include reductions in human error and greater problem ownership

Milestone 3: Improve compliance to best practice

• Data used to refine and transfer core routines to front line teams.

• Measurable gains include enhanced process control and yield improvement.

Milestone 4: Identify and remove minor defect causes

• Data used to reduce unplanned and then planned interventions; support low-cost automation.

• Measurable gains include productivity gains and improved material yield.

The improvement project work is executed as part of daily operations and supports:

• The delivery of business plans and strategic goals,

• Rule based decision making and task transfer,

• Measurable progress towards world-class operational performance,

• Development of self correcting team capabilities.

Where an organisations is embracing advanced technology or digitisation, TPM Excellence provides a roadmap to unlock stranded data from PLCs or make use of smart sensor technologies by providing answers to questions about:

• What data to capture,

• How to capture it,

• How to engage and empower the workforce with new insights,

• How to transfer lessons learned across the business to maximise impact.

The Competitive Advantage

The TPM Excellence programme provides your teams with the skills to deliver faster, better results through smarter use of data.

That enhances operational performance, accelerates the delivery of gains, and builds genuine ownership of business problems where they happen.

Let’s

Contact us to discuss how we can help unlock these capabilities across your organisation to accelerate your path to industry-leading performance.

Traditionally, data collection has been focused on reporting what happened and when things went wrong, to explain why, or worse, to allocate blame.

To truly unlock the value of data, leaders, planners, and front-line teams need to develop the capability to ask the right questions, transform raw data into actionable insights, and drive performance improvements. This process goes beyond numbers; it is about:

• Understanding the causal factors behind the numbers and the decisions they inform.

• Empowering people to act on that information quickly.

• Using real-time feedback to refine responses.

• Sharing lessons learned to multiply gains and drive a proactive, continuous improvement culture.