Philosophy - Page 2
Your Machines Print Your Paycheck
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RECLAIMING 1 HOUR PER DAY
🏭 Example Scenario: Supervisor implements changes (training, daily maintenance planning, walkabout) that reduce 1 hour of downtime/lost time per day.
Just 1 hour of lost time per day = 365 hours per year—that’s 15 full days of production gained annually!
Imagine all the preventive maintenance (PM) tasks your team could complete in those 15 days—tightening, lubricating, cleaning (TLC)—which are the foundation for reducing breakdowns.
When your maintenance team manages to eliminate just 1 hour of lost time per day, you unlock 2 powerful opportunities:
1. Increase Productivity → More output, more revenue.
2. Reduce Downtime Costs → Less loss, more margin.
The Business Case: 1 Hour Can Change Everything
What’s the value of increasing your production yield by just 1%?
Say, you produce 1,000 extra bottles per day from a 1% capacity increase.
That’s 30,000 extra bottles per month.
If your profit margin is RM1 per bottle,
That’s RM30,000 in additional profit each month!
How about 4% increase in capacity?
That's equivalent to 1 hour of extra production uptime per day.
That could mean an extra RM120,000 in profit per month! 😄
Your Machines Print Your Paycheck
Most teams ignore downtime because they’ve never put a Ringgit value on it. Once they do—the urgency becomes obvious.
What’s the Cost of Just 1 Extra Minute of Downtime?
According to Senseye Report (The True Cost of Downtime 2024), the average FMCG plant experiences:
27 hours of unplanned downtime per month
The cost of 1 minute of downtime as high as US$600.
Let’s assume for Malaysia, just RM100 per minute.
3 technicians lost 1 extra hour hunting for WD-40 & sledgehammer.
That unnecessary delay cost your plant RM6,000 per lost hour!
Over a month, if downtime reaches 27 hours, that’s RM162,000 in lost revenue! 😲
This isn’t a training issue—it’s a profit leak.
And it keeps leaking every day you delay.
The ENABLER
Proper Maintenance Saves Even More
Proper Maintenance Saves Even More
PM is your best defense against costly breakdowns and premature failures.
Like maintaining a car, regularly inspecting, tightening, lubricating, and cleaning (TLC) your equipment extends its lifespan and avoids big repair bills.
For example: by routinely cleaning motors, your team can prevent overheating and avoid early failures—saving you from expensive part replacements.
Reclaim Time Without Hiring More Staff
Reclaim Time Without Hiring More Staff
Let’s say your maintenance team revamps their pre-shift toolkit prep process. Now, 8 technicians no longer waste 1 hour waiting for tools in the morning.
That’s 8 hours of reclaimed time—the equivalent of having 1 extra technician on your team, without paying another salary!
This reclaimed time can now be used to perform essential TLC tasks and respond faster to production needs.
TLC is your first line of defense against equipment failure.
Point: You don’t need more people—you need to reclaim the hours you already pay for.
SUMMARY: By reclaiming just 1 hour of lost time per day, you and your team are cashing in on the opportunities to create more output, more revenue, less loss, more margin.
Increase Productivity → It could be an extra RM120,000 in profit per month! 😄
Reduce Downtime Costs → It could be as high as RM162,000 in lost revenue! 😲
Your Machines Print Your Paycheck.
So, how do we do that?
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