We help manufacturing companies eliminate losses, strengthen equipment reliability, improve safety performance, and reduce conversion costs—by deploying practical OPEX/TPM systems that operators and technicians truly own.
If these problems look familiar, we can help you move from firefighting to stable, predictable performance using practical OPEX/TPM routines and strong shop‑floor ownership.
Breakdowns, short stops, and recurring failures that constrain output and drive overtime.
Availability, performance, and quality losses hidden inside daily operations.
Reactive maintenance and weak daily equipment care leading to frequent disruptions.
Unsafe conditions and weak standard work that increase risk and disrupt operations.
Lost capacity at bottlenecks, poor flow, and high changeover/start‑up losses.
Quality losses and rework that drive conversion costs up and weaken delivery performance.
Limited ownership from operators and technicians; little empowerment to improve.
Waste + downtime + rework + reactive maintenance raising cost per unit.
Reactive > 80% and proactive < 20% — we build routines that steadily flip that ratio.
Start small, prove impact fast, then scale. Engagements can begin with a focused assessment and roadmap and expand through a pilot + staged roll‑out.
Make losses visible (OEE & cost), prioritize the vital few, and execute focused improvement with measurable results.
Deploy pillars, define roles, coach leaders/operators/technicians, and implement audits to sustain gains.
Move from run‑to‑failure to proactive maintenance through daily equipment care, PM optimization, and reliability systems.
Stabilize work areas with visual standards and discipline that support safe, efficient execution.
Attack chronic losses on constrained assets with cross‑functional teams and structured problem solving.
Practical systems (CI apps / CMMS workflows / analytics) to support execution without adding bureaucracy.
Representative transformations documented in your materials.
TPM implementation across 30+ factories in 13 countries with pillar roll‑out, coaching, and certification.
Loss deployment, OEE concept, DMS at machine level, and pillar roll‑out across US & Mexico plants.
Multi‑site transformation from firefighting to proactive maintenance using pilot + staggered expansion and sustainment audits.
Led by Ahmet Caglayan — global manufacturing & operations executive focused on TPM, operational excellence, reliability, and culture change. View LinkedIn profile.
Operational Excellence • TPM • Asset Reliability
Clear targets, visible loss tracking, leader standard work, and shop‑floor routines that build ownership for operators and technicians.
Rapid diagnosis and roadmap aligned with your business goals and constraints.
Pilot + Kaizen + coaching to build momentum and capability.
Audits, governance, and routines that prevent backsliding.
Examples of visual management, workplace organization, standards, and practical improvement practices.
Use the form below. Share your top pain points and targets—downtime, OEE, reliability, safety, productivity, engagement, conversion cost, scrap/defects/waste—and we’ll propose the best starting point.
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