An automotive parts manufacturer operating 24/7 faced chronic breakdowns after years without strong maintenance leadership. Daily disruptions, overdue PMs, and reactive “firefighting” hurt productivity and profitability. A structured TPM-based improvement program introduced skills assessment, prioritized scheduling, downtime analysis, contractor support, visual management, and oil sampling. Results included a 48% reduction in conveyor downtime incidents, a 24% reduction in downtime minutes, closure of 400+ overdue work orders, and improved uptime through proactive maintenance and accountability systems.

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