Predictive Maintenance
Use equipment and condition data to anticipate failures early.
Culture of effectiveness and reliability
Total Productive Maintenance Consulting
Effectiveness and reliability start where production and maintenance stop working in silos
Maintenance consulting services
Reactive maintenance is the industry default. It doesn’t have to be yours.
We reframe this relationship through our TPM Consulting, embedding predictive and planned approaches into daily routine, so maintenance becomes what it’s designed to be: a support function that keeps production running, not a firefighting crew called in after the damage is done.
Maintenance Excellence Levers
Building a productive maintenance system
Kobetsu KAIZEN™
- Increase Overall Equipment Effectiveness – OEE – by following a structured approach to eliminate failures.
- Develop problem-solving capabilities to identify and eliminate root causes effectively.
Maintenance Results
See how we transform maintenance operations
Reactive vs. Reliable Maintenance
A practical approach to lasting change
Traditional Approach
- Repair when broken
- Focus on equipment availability
- Barriers between production and maintenance
Lean Approach
- Prevent issues upstream
- Focus on full equipment effectiveness
- Collaborative maintenance
KAIZEN™ TESTIMONIALS
What our clients have to say
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We use the Hoshin Kanri methodology to execute an annual strategy across the company, cascading it into sub-strategies within different departments, which are in turn deployed across various management boards.
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Now we’d never go back. It’s just been brilliant, completely changed everybody’s mindset. The positivity is just brilliant. The results are there to see.
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I have been deeply inspired by the entire KAIZEN™ methodology since I began to understand this process of small improvements that enhance day-to-day work.
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We have developed and deployed a Lean Manufacturing philosophy based on the Change Management System promoted by Kaizen Institute. The goal is to bring consistency to industrial management across all our plants, grounded in data-driven management, lean production, and people as the primary driver.
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Our partnership with Kaizen Institute was essential to our operational transformation, fostering a continuous improvement culture focused on the end customer. We were able to reinvent our processes, grow efficiency, and focus our teams on what truly adds value.
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Instead of offering off-the-shelf solutions, Kaizen Institute dives deep into processes to understand challenges and identify opportunities.
FAQ
What you need to know
When breakdowns dictate the production schedule: firefighting maintenance teams, recurring failures on critical equipment, rising maintenance costs and spare parts stock, low or unstable OEE, and aging assets whose replacement business case keeps being postponed. Reactive maintenance is the most expensive maintenance there is; it just spreads the cost across production losses.
It rebuilds the maintenance system around total productive maintenance principles. Operators take ownership of basic equipment care through autonomous maintenance, planners shift work from reactive to preventive, failure data drives criticality-based strategies, and predictive maintenance technologies are applied where their cost is justified by the risk. Maintenance and production stop working as adversaries.
The program starts from the losses of not stopping: every unplanned breakdown costs more time than the planned intervention that would have prevented it. Planned windows are phased in on critical equipment first, often inside existing changeovers and low-demand periods, and the recovered reliability quickly funds the discipline.
Typical trajectories show breakdown reduction and OEE gains on pilot equipment within months, followed by falling maintenance costs and spare parts inventory as the preventive plan matures. MTBF rises, MTTR falls, and over a longer horizon asset life extends, deferring capital expenditure that was assumed inevitable.