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Maintenance Programs

Total Productive Maintenance

Plant-Wide and Maintenance Goals: To be considered world class these days, you have to look well beyond just 100% on-time delivery.
  • Maintenance costs < 5% of total sales
  • Uptime availability > 90%
  • Backlog compliance > 95%
  • Work allocation analysis 80/20 rule or better (80% TPM - 20% emergency)
  • Autonomous maintenance activities account for at least 25% of Total Productive Maintenance work
  • Predictive methods account for 50% or greater resource allocation for maintenance work
  • 5S and monthly layered process audits are in effect plant-wide
  • 90% or better Overall Equipment Effectiveness
  • Spare parts are 90% or greater on time delivery

Does running at world class status seem lofty or even impossible? Not at all.

Through a well planned, 5-day Rapid Improvement Event, an effective TPM and Maintenance Excellence Strategy can help transform your company culture into a world class provider of reliable materials and services. MMTC can enable companies to see their waste in the current maintenance processes and provide proven solutions for rapid improvement. Planned maintenance activities are an opportunity to save time and money. MMTC shows clients how to transform the view of traditional maintenance as a cost burden into a nimble customer and cost focused service provider.


  • $180 million in annual lost revenue is directly attributed to poor maintenance practices in U.S. manufacturing firms
  • Re-establishing your maintenance approach from a “cost-burden-failure” to a “cost-savings-success” typically will gain a minimum of 6 to 1 payback
  • Machines that are proactively maintained general consume 5% to 10% less energy
  • Simple autonomous (operator-based maintenance) generally eliminates 50% to 70% of unplanned stoppages
  • Inadequate maintenance practices typically waste 20% to 50% of spare part budgets unnecessarily
  • Organizations that operate with traditional “run till failure” methods, typically waste over 30% of every dollar spent on maintenance repairs


What if your organization could improve availability, performance efficiency and quality of just one machine?


ANSWER: Increased run time of good parts = Increased EBIT of $32,200 from one machine.


Where is your hidden week hiding?


ANSWER: 10 minutes per day or 42 hours gained per year.

Training and Implementation

12 hour TPM Workshop with Application

Appointment based on-site over 1.5 days.
On-site 1.5 days of training. Course is designed to teach operations the philosophy, and skills necessary to transform productive maintenance activities from a cost burden to a cost savings part of the business. Training includes hands-on application in a defined area or specified machine on the production floor.

40 hours TPM Kaizen

Appointment based on-site over 5 days, plus pre-event preparation and post-event follow-up.
This program is designed for all levels of maintenance and supervision within an organization that is in the manufacturing supply chain. This application could be helpful to all organizations; however, Beyond TPM Maintenance will have a strong manufacturing focus.

Maintenance Excellence Strategy

mes2MMTC's Maintenance Excellence Strategy (MES) training program offers a comprehensive, hands-on approach to enable maintenance and reliability planners to access best practice methods and applications for their production equipment. Adopting an internal MES helps your organization to successfully implement proven techniques which eliminate waste and boost profits (lower costs and improved care of equipment). MES programs are designed to build upon MMTC's Total Productive Maintenance strategy. This approach can completely transform the care and management of assets. This enables manufacturers to grow, often without the need for additional capital expenditures.


  • Breakdown Maintenance Strategy (BMS) - Identifies the costly aspects of a “run till failure” approach to operating and maintaining equipment. Examine the best practice methods to measure and remove the costly aspects of downtime. BMS transforms the maintenance department into a knowledgeable service function for operations.
  • Enhancing Green Initiatives - Introduces the latest green methods, tools and standard techniques designed to lower operational costs. Competition today demands we examine opportunities to make better choices to reduce our global carbon footprint and stimulate and cost saving green initiatives.
  • Preventative Maintenance Conditioning - Maximize the best approaches to a condition-based maintenance strategy by examining the steps required to build an effective and robust maintenance strategy with waste-free processes.
  • Predictive Maintenance Reliability - Utilizing specialty tools and techniques which assists maintenance departments to evolve from cost-burdens to cost-savers. Maintenance and reliability engineers benefit by application sensory detection tools that promote effective capacity utilization of equipment.
  • Early Equipment Management and Error Proofing - Transforming equipment into maintenance-friendly reliable assets which provide “above human sensory intelligence” with simplicity built in. Dividing equipment into zones of importance while utilizing maximum efficiency planning, historical data and best practice methods to improve the design of the equipment.


  • Gain ability to grasp a clear understanding of improvements made at the shop level can dramatically improve the overall performance of the company
  • Enhance skill level for troubleshooting using tools to overcome perceived barriers in current-state manufacturing settings necessary to support and improve the maintenance department to higher levels of performance
  • Use MES to offset a lack of ability to run equipment effectively, while driving out the need to procure funds to purchase additional equipment
  • Enhance maintenance strategies to develop best practices that promote capable processing and dramatic reduction of costly production defects


  • Poor maintenance practices costs $180 million in annual lost revenue to U.S. manufacturers
  • Machines that are pro-actively maintained generally consume 5% to 10% less energy
  • Simple operator based maintenance typically reduces 50% to 70% of unplanned stoppages
  • Inadequate maintenance practices waste 20% to 50% of spare part budgets unnecessarily
  • Organizations that operate with traditional “run till failure” methods, typically waste over 30% of every dollar spent on maintenance repairs
  • Shifting maintenance from a “cost-burden to a cost-savings” approach offers a greater than 6 to 1 ROI

pdaFor more information about MMTC's Maintenance programs, contact us at 888-414-6682 or via email at inquiry@mmtc.org.