Ratcheting Up Improvement Gains Through

Programme Overview

The TPM Excellence Programme is designed to enhance manufacturing performance and resilience.

The programme begins by assessing current operations and aligning leadership on improvement priorities. This is followed by a practical, hands-on phase centred around asset improvement pilots. The goal is to drive measurable results through team-led initiatives, embedding continuous improvement into daily routines and ultimately scaling successful practices across the organisation to achieve sustained excellence and meet future challenges.

The core of the support programme is a structured improvement journey that delivers immediate results while building the capabilities your organisation needs for the future. This simultaneously develops:

Leadership Competence.
Execution Excellence.
Planning and Performance Analysis.

Laying the Foundation for Excellence

The programme starts by building a clear, evidence-based understanding of your current operations and creating alignment around a practical path forward. It involves:

Conducting a comprehensive diagnostic assessment to evaluate the current state of the systems that drive both performance and change. This includes:
- Operational systems such as process control, data use, standardisation, and Leadership Standard Work
- Improvement systems such as policy deployment, collaboration practices, and performance analysis
Facilitating “Plan the Plan” working sessions for leadership. These are designed to:
- Develop a shared view of the full improvement landscape
- Align on priorities that matter most to the business
- Define and launch a pilot programme based on real-world, practical projects
- Bring visibility to barriers and actively engage all levels in designing new ways of working
Partnering with internal teams to establish a structured rhythm of feedback and reflection. This ensures:
- Timely capture of lessons learned
- Continuous adjustment and alignment of activities
- Scalable delivery of improvement gains across your wider operations

A Practical, Hands-On Approach

The programme mobilisation kicks off with a 3–4 day interactive workshop, blending theory with practical application. Participants:

Learn TPM principles and techniques and case studies.
Apply their knowledge in teams to real assets using the Asset Improvement Plan workbook—a structured, hands-on guide that drives understanding, root cause analysis, and countermeasure development.

Teams conclude the mobilisation workshop by capturing lessons learned and identifying improvement barriers. These insights feed into a “Plan the Plan” session that sets priorities and launches a pilot programme led by a cross-functional Core Team.

Driving Results Through Pilot Implementation

Over a quarterly cycle, the Core Team meets 8–10 times to work through each stage of the Asset Improvement Plan:

Assess asset condition and performance
Identify problem hotspots
Measure improvement potential
Develop and implement countermeasures

Simultaneously:

Functional leaders use case studies from the mobilisation workshop to coach and align their teams.
Cross-functional alignment ensures improvement actions support business objectives.
Routine performance management processes embed the work into day-to-day operations.

Scaling Up: The Pilot Lessons Learned

In addition to improving pilot asset performance, the pilot phase highlights gaps and barriers to improvement and how to create a sustainable “improvement glide path” led by front-line teams, backed by senior leaders.

The pilot support provides:

Coaching for team leaders to develop front-line capabilities.
Increased engineering capacity by reducing unplanned downtime.
Stronger collaboration between production and maintenance teams.

Pilot-phase lessons include:

Extending component life by reducing wear.
Cutting human error, a major cause of downtime.
Improving data use and ownership of improvement.
Freeing up time to address precision and quality issues.

To scale these gains, we work with senior leaders to develop a bespoke Improvement Roadmap. That sets out a series of milestones setting out a staged journey to stability and higher-level performance. Each stage:

Builds capabilities
Reinforces consistent performance
Prepares your organisation for future challenges

Even mature operations benefit—systemic variation and unplanned events mean there’s always room to learn and improve. Leadership engagement is key, and this programme enables leaders to link local actions to strategic outcomes.

Matching TPM Excellence Priorities with Business Goals

Programme delivery relies on practical, real-world projects led by team leaders who coach their peers. Rollout is aligned with business priorities and embedded within your existing performance management framework.

Key delivery mechanisms:

1. Establishing a Quarterly Improvement Cadence

Smooth transitions in roles and responsibilities
Targeted performance analysis and problem solving
Recognition of achievements to reinforce a culture of improvement

2. Creating an Improvement Pull

Assigning operational hotspots to frontline teams
Strengthening ownership, standardisation, and continuous learning

Why This Matters Now

The TPM Excellence Programme is a proven pathway to stronger results—financially, operationally, and culturally. It enables your business to meet shifting expectations and navigate future disruption with confidence.

Let’s explore what this could look like in your organisation. Our support begins with:

A diagnostic to assess current systems and improvement readiness
A collaborative planning session to align goals and launch a tailored pilot
Ongoing coaching to embed learning, track progress, and scale success

You’re not alone in this. Partner with us to unlock the full potential of your operations—and build a high-performing, resilient future.

For senior manufacturing managers, that not only delivers operational enhancement—it enables a disciplined, inclusive, and data-driven approach that continuously elevates performance and secures long-term competitive advantage.