Fast moving consumer goods (FMCG) industries are some of the industries that are characterized by manufacturing of vast variety of products whose profitability bears sustenance in output volumes. The need to maintain high output and outcompete competitors in the global market lies with apprenticing various equipment efficiency enhancement strategies. One of the impediments to the attainment of high efficiencies in these industries is the amount of waste loss incurred during manufacturing, predominantly resulting from equipment failures. A fast-moving consumer goods industry in the line of match sticks manufacturing was plagued with exorbitant waste losses generated by equipment failures which impacted adversely on the goal of increasing their manufacturing output. The paramountcy of the problem acuminated directly to the absence of an equipment reverse deterioration approach in their maintenance operating system. This was emulated by significant evasions of material during processing which resulted in material contamination and presented major write-off losses and reduced output. The magnitude of the problem in this organization goaded the study to derive an aim of adopting the total productive maintenance (TPM) 4-phases to zero breakdowns to circumvent waste generation from equipment failures and maximize manufacturing output. The results of the study were a simplified equipment reverse deterioration approach that saw a significant reduction in waste and an improved output glide path for the organization.

Keywords

Output, Waste, Equipment failures, Reverse deterioration and Efficiency.