Philosophy - Page 2
Your Machines Print Your Paycheck—Let’s Prove It
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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 foundations 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 by just 1%?
Let’s say your line runs at 70 bottles/minute.
Just 14 extra minutes of uptime per day = 1% more capacity
= That’s ~1,000 more bottles/day
= That’s 30,000 more bottles/month
If you earn RM1 profit per bottle,
That’s RM30,000 extra profit/month from just 1%!
Imagine unlocking 4% more?
That’s an extra RM120,000 per month 😄
All from reclaiming 1 hour of lost time a day.
Your Machines Print Your Paychecks.
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’s 2024 report, FMCG plants suffer:
27 hours of unplanned downtime per month
With downtime costing as much as US$600 per minute.
Let’s be conservative for Malaysia:
RM100 per minute
= RM6,000 per hour
= RM162,000 per month (at 27 hours of downtime)😲
Imagine this:
3 technicians spend 1 extra hour hunting for a WD-40 and sledgehammer…
That’s RM6,000 down the drain.
And it happens more often than anyone wants to admit.
This isn’t a training issue. It’s a profit leak.
And it keeps leaking every day you delay fixing your systems.
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 → That's equivalent to 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 Paychecks.
So, how do we do that?
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