Case Study : Lean Manufacturing Success

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Client Description

Regional / Global manufacturer of various confectionary products and snack foods.


After completing a detailed assessment of several client manufacturing operations, TPG recommended the implementation of Lean TPM tools, specifically several operational “pillar” best practices to address gaps in internal operating efficiency and throughput.


Implement the proper TPM tools to achieve a 10-15% improvement in Overall Equipment Effectiveness (OEE) while building operating personnel skills and capabilities.

TPG Approach

TPG reviewed the assessment outcomes with key decision makers and determined a pilot site to implement several TPM practices designed to improve operating efficiency . The Autonomous Maintenance and Education and Training pillars were implemented beginning in the summer of 2010.


By the fall of 2011 the client realized operational efficiency improvements of 20-40% across several production lines yielding over $600k in spending and waste reductions on a yearly basis. Also, training and skill development programs were redesigned for all new entry level employees based on the techniques introduced through TPM.

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