This article sets out the role of maintenance in supporting Lean Manufacturing and how this requires a change in emphasis from the traditional approach to maintenenance.

The Operations Director was concerned.  The company was making great strides in improving productivity, quality and cost performance yet to the director’s eyes, the Lean revolution had bypassed the maintenance function.

Talking to maintainers the Director found that in their view, Lean makes the maintainers job more difficult and more stressful.  It seemed like the attitude of their maintenance department was holding them back but was this cause or effect?  When a problem occurred the problem was fixed but too often it seemed to require a gigantic effort. 

Their record keeping was poor, problem solving approach ad hoc and skill levels varied.  With so much fire fighting going on, although they were coping, it was obvious that they were not in control and that it was not going to change without a special effort...........

The Lean Maintenance toolbox drives the change in maintenance role from “fixing breakdowns” to adding value. This includes the transfer of routine maintenance activities to production personnel to release maintenance and specialist time from routine tasks to focus on optimisation and process improvement.

The Take Away
The article provides an insight into the impact of maintenance on organisational effectiveness and direct costs using case study data. It also sets out practical steps to deliver equipment reliability and process improvement to support Lean and Six Sigma improvement processes. This includes a review process to engage the maintenance lead team with helping the organisation to achieve its full potential.

Download Article: What is Lean Maintenance?

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