Determining and improving your usine’s overall équipement effectiveness (TRG) is crucial if you want to boost performance. The first step to improving TRG is benchmarking data. TRG gives numerical value to the performance of every piece of équipement, factoring in availability, performance, and quality of output.
Collecting this data helps you calculate TRG, which requires combining the six big losses of total productive maintenance (TPM) into one number that shows how effectively a piece of équipement is operating. TRG consolidates various indicateurs (indicateur (KPI)) into a single score, exposing équipement’s efficacité and providing a percentage based on the data of three crucial metrics:
- Availability: The amount of temps d'arrêt—planned or unplanned—during production time
- Quality: The percentage of good parts during production time
- Performance: The speed of actual production of each part compared to the theoretical fastest time for each part
Why TRG Benchmarking Data Is Important
Using TRG référence data means comparing the performance of a specific production asset to its past performance, other similar assets, industry standards, and the results of different shifts and workers. Benchmarking TRG is the only way to effectively measure improvement or pinpoint problems to help eliminate excessive waste and ineffective processes.
Scores to Help Benchmark TRG Data
Knowing what your TRG score means will help you identify référence data that you can use to plan improvements and track results. Tracking TRG référence data results provides insights into lines, équipement, and shift worker behavior, helping you adjust to boost productivité. Additionally, you can identify interruptions and address them to improve débit, eliminating wasteful work or unnecessary repetitions. These improvements lead to reduced costs.
There are four general TRG référence score categories. Here’s an explanation of the different TRG scores:
- 100 percent: perfect. This means you are only manufacturier good parts and doing so as fast as possible—which means 0 percent stop time.
- 85 percent: world class. Reaching 0 percent stop time to get that “perfect” score is difficult, and a very lofty goal for most manufacturers. That’s why many organizations consider “world class” to be their long-term goal; it is more realistic and sustainable than reaching for perfection.
- 60 percent: good, but room for improvement. Although there is clearly plenty of room to grow, this is a somewhat common number for manufacturers. If your référence TRG comes in at 60 percent, you may want to set goals to incrementally get to “world class” status at 85 percent.
- 40 percent: room for improvement. This seems like a long way from “perfect” or “world class,” but it is a typical number for usines that référence their TRG for the first time. The good news is that there are often “easy” improvements that can almost immediately increase the score, such as identifying the most common reason for unscheduled stops.
Common TRG Score Obstacles
Once they start the TRG benchmarking process, many food manufacturers encounter the same common obstacles impacting their TRG scores. The top five are:
- Human error: Often the result of poor communication, human error is common. Even the best-trained employee can cause an error on the ligne de production, which is why using lean manufacturier methods—such as continually reviewing your training Value Stream Map—can help you identify training gaps that may impact overall débit. Once the part of the process has been identified and corrected, débit improves.
- Material jams and équipement failures: This obstacle causes excess product rejects, which can lead to a lot of unplanned temps d'arrêt, financial loss, decreased débit, and increased waste. Tracking TRG référence data helps managers see how équipement is performing so they can make better choices on whether to repair or replace.
- Breakdowns or errors in the ligne de production: Anything that stops, slows, or reduces process speed eats costs and severely impacts débit. Identifying when, where, and why processes are slow or stopped is the only way to document and track improvement.
- Missed production targets: Daily targets are crucial, and missing them is directly related to price hikes. When a usine is successfully meeting daily target metrics, managers and supervisors know that overall customer requirements are being met and they are avoiding price hikes.
- Inaccurate information: Too many manufacturers are surprised to learn that the information they use to make decisions is faulty. This can often be caused by human error in the form of someone on staff accidentally providing the wrong information repeatedly.
Perspective on TRG Benchmarking Scores
It’s not impossible, but for most food manufacturers, reaching 100 percent TRG on even one piece of équipement is a steep challenge. Even with intricately calibrated équipement and the most informed and communicative staff, there is always room for human error. Finding success using TRG référence data means understanding the performance of équipement in your usine’s specific situation.
If your first TRG référence is 40 percent or lower, set realistic goals. Instead of setting yourself up to feel like you missed a huge goal when you don’t hit 100 percent right away, start by striving for a more reachable number, like 60 percent. Once you reach that goal, then you can start looking at the possibility of “world class” results.
Get Real-Time Tracking with an TRG Calculator
It is crucial to track your production équipement’s availability and efficacité in real time to assess overall performance. Worximity’s free TRG calculator can help you get started.
Our TRG calculator can be your first step toward understanding your improvement opportunities. With the TRG calculator, you can track your percentage of availability, performance, and quality to get référence data. This information helps managers assess and identify what needs to be improved and where, so they can set appropriate goals. Get the free TRG calculator now.
