Lean Maintenance

Reduce Costs, Improve Quality, and Increase Market Share


  • Ricky Smith, CMRP,Reliability Strategy Leader Ivara Corporation
  • Bruce Hawkins, Life Cycle Engineering, North Charleston, SC, USA

What is "Lean?" Whether referring to manufacturing operations or maintenance, lean is about doing more with less: less effort, less space, fewer defects, less throughput time, lower volume requirements, less capital for a given level of output, etc. The need to provide the customer more value with less waste is a necessity for any firm wanting to stay in business, especially in today's increasingly global market place. And this is what lean thinking is all about.Lean Operations are difficult to sustain. More Lean Manufacturing Plant Transformations have been abandoned than have achieved true Lean Enterprise status. There are solid and recurring reasons for both of these conditions. The most significant of these reasons is that production support processes have not been pre-positioned or refined adequately to assist the manufacturing plant in making the lean transformation. And the most significant of the support functions is the maintenance operation, which determines production line equipment reliability. Moving the maintenance operation well into its own lean transformation is a must-do prerequisite for successful manufacturing plant - or any process plant - Lean Transformations. This Handbook provides detailed, step-by-step, fully explained processes for each phase of Lean Maintenance implementation providing examples, checklists and methodologies of a quantity, detail and practicality that no previous publication has even approached. It is required reading, and a required reference, for every plant and facility that is planning, or even thinking of adopting "Lean" as their mode of operation.
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Reliability Engineers, Maintenance Engineers, Technicians, Mechanical Engineers


Book information

  • Published: May 2004
  • ISBN: 978-0-7506-7779-0

Table of Contents

1. Common Ground1.1 The History and Evolution of Learn 1.2 Lean Manufacturing and Lean1.3 Governing Principles: What is Lean and What is Not1.4 Relationships in the Lean Environment1.5 Summary of Lean Concepts2. Goals and Objectives2.1 The Primary Goals and Objectives of Manufacturing2.2 Integrating Lean Goals with Maintenance Goals2.3 The Need for, and Gaining, Commitment2.4 Measuring Progress3. Total Productive Maintenance3.1 TPM (Fine-Tuned) is Lean Maintenance3.2 Fine-Tuning TPM Using Reliability Centered Maintenance4. Pre-Planning for Lean Maintenance4.1 Gaining Knowledge/Imparting Knowledge4.2 The Transformation Roadmap4.3 Lean Maintenance Transformation Kick-Off Meeting4.4 Phase 1: Developing the POA&M and the Master Plan5. Launching the Master Plan (POA&M)5.1 The Sequence of Events6. Mobilizing and Expanding the Lean Transformation6.1 Mobilizing Lean in the Maintenance Organization (Phase 4)6.2 Expanding the Lean Maintenance Transformation7. Sustaining Lean – Long Term Execution7.1 Sustaining Continuous Improvement (Phase 6)Appendix A: Checklists and FormsAppendix B: Documentation ExamplesAppendix C: Articles of InterestGlossaryIndex