Total Productive Maintenance (TPM)

is a proactive maintenance strategy designed to maximise equipment efficiency and minimise downtime in manufacturing.

It involves empowering all employees, from operators to managers, to take responsibility for maintaining machines through regular maintenance, cleaning, and inspections.

At Cogne U.K. Limited we use TPM to focus on preventing breakdowns, improving equipment reliability, and ensuring smooth production processes by promoting continuous improvement and teamwork.

This approach helps increase productivity, reduce maintenance costs, and extend the lifespan of equipment.

Root Cause Analysis (RCA)

is a problem-solving method used to identify the underlying cause of an issue or failure. Instead of just addressing symptoms, RCA aims to find and fix the root cause to prevent the problem from recurring.

It involves systematically analysing data, asking "why" multiple times, and using tools like fishbone diagrams or the 5 Whys technique to trace issues back to their origin. At Cogne U.K. Limited we use RCA to troubleshoot so we can improve processes and prevent future errors.

Continuous Improvement

Often associated with the Japanese term Kaizan, is a business philosophy focused on making ongoing, incremental enhancements to processes, products, or services.

Rather than pursuing major overhauls, continuous improvement encourages small, consistent changes that, over time, lead to significant gains in efficiency, quality, and performance. This approach engages all employees in identifying opportunities for improvement, fostering a culture of innovation and collaboration.

By continuously refining operations, Cogne U.K. Limited has reduced waste, optimised productivity, and we stay competitive in a rapidly changing market.

Continuous Flow

...is a production method focused on maintaining a steady, uninterrupted movement of products through each stage of the manufacturing process. Unlike batch processing, continuous flow ensures that work-in-progress moves smoothly from one step to the next without delays or bottlenecks.

Cogne U.K. Limited uses this approach to reduce waiting times, minimises waste, and improve overall efficiency by keeping operations in constant motion. Continuous flow is a key principle in lean manufacturing, aimed at optimising productivity, reducing lead times, and delivering consistent, high-quality results.

Poka Yoke

...is a Japanese term meaning "mistake-proofing" or "error prevention," used in processes and systems that prevent defects or human errors from occurring.

The goal of Poka Yoke is to create mechanisms or tools that either stop mistakes before they happen or make them immediately detectable, ensuring quality and consistency.

These can include physical devices, alarms, or visual cues that guide workers to perform tasks correctly. By reducing the chance of errors, Poka Yoke enhances product quality, increases efficiency, and minimises costly rework or defects.

Kanban

... is a visual workflow management system used to optimise and streamline production processes. It relies on a board, often divided into columns representing different stages of work, with cards or signals to represent tasks or products.

As tasks move through the stages—from "to-do" to "in progress" and "completed"—the Kanban system helps teams monitor progress, manage work-in-progress limits, and improve efficiency.

By visualizing the flow of work and identifying bottlenecks, Kanban enhances productivity, reduces waste, and promotes continuous improvement in both manufacturing and service industries.

Overall Equipment Effectiveness (OEE)

...is a key performance metric used in manufacturing to assess the efficiency and productivity of equipment. It measures how effectively a machine is utilised by analysing three factors: **Availability** (downtime), **Performance** (operating speed), and **Quality** (defects).

OEE provides a clear understanding of how well equipment is functioning by highlighting losses in production and identifying areas for improvement.

A perfect OEE score of 100% means the equipment is operating with no downtime, at maximum speed, and producing defect-free products. This metric helps companies improve machine performance, reduce waste, and increase overall productivity.

6S

...is a workplace organisation method derived from lean manufacturing principles aimed at improving efficiency, safety, and productivity. It consists of six key steps: Sort, eliminating unnecessary items; Set in Order, organising tools for easy access; Shine, keeping the workspace clean; Standardise, creating consistent procedures; Sustain, maintaining these practices long-term; and Safety, ensuring a safe environment.

By following 6S, Cogne U.K. Limited has reduced waste, improved workflow, and enhanced overall workplace conditions.