Lean Maintenance

Lean Maintenance

Reduce Costs, Improve Quality, and Increase Market Share

1st Edition - May 19, 2004

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  • Authors: Ricky Smith, Bruce Hawkins
  • Hardcover ISBN: 9780750677790
  • eBook ISBN: 9780080478906

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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.

Key Features

* A continuous improvement strategy using new "lean" principles

* Eliminate wasteful practices from your manufacturing or chemical processes, increasing the profitability of your plant

* Save thousands of dollars a year on new equipment by keeping your existing equipment maintained using this revolutionary method


Reliability Engineers, Maintenance Engineers, Technicians, Mechanical Engineers

Table of Contents

  • 1. Common Ground
    1.1 The History and Evolution of Learn
    1.2 Lean Manufacturing and Lean
    1.3 Governing Principles: What is Lean and What is Not
    1.4 Relationships in the Lean Environment
    1.5 Summary of Lean Concepts

    2. Goals and Objectives
    2.1 The Primary Goals and Objectives of Manufacturing
    2.2 Integrating Lean Goals with Maintenance Goals
    2.3 The Need for, and Gaining, Commitment
    2.4 Measuring Progress

    3. Total Productive Maintenance
    3.1 TPM (Fine-Tuned) is Lean Maintenance
    3.2 Fine-Tuning TPM Using Reliability Centered Maintenance

    4. Pre-Planning for Lean Maintenance
    4.1 Gaining Knowledge/Imparting Knowledge
    4.2 The Transformation Roadmap
    4.3 Lean Maintenance Transformation Kick-Off Meeting
    4.4 Phase 1: Developing the POA&M and the Master Plan

    5. Launching the Master Plan (POA&M)
    5.1 The Sequence of Events

    6. Mobilizing and Expanding the Lean Transformation
    6.1 Mobilizing Lean in the Maintenance Organization (Phase 4)
    6.2 Expanding the Lean Maintenance Transformation

    7. Sustaining Lean – Long Term Execution
    7.1 Sustaining Continuous Improvement (Phase 6)

    Appendix A: Checklists and Forms
    Appendix B: Documentation Examples
    Appendix C: Articles of Interest

Product details

  • No. of pages: 304
  • Language: English
  • Copyright: © Butterworth-Heinemann 2004
  • Published: May 19, 2004
  • Imprint: Butterworth-Heinemann
  • Hardcover ISBN: 9780750677790
  • eBook ISBN: 9780080478906

About the Authors

Ricky Smith

Ricky has over 30 years in maintenance and reliability as a maintenance manager, maintenance supervisor, maintenance training specialist, field engineer, maintenance mechanic, maintenance consultant and is a well known published author. Ricky has worked with maintenance organizations in hundreds of facilities, industrial plants, ships, etc, world wide in developing reliability, maintenance and technical training strategies.

Prior to joining Allied Reliability in 2008, Ricky worked as a professional maintenance employee for Exxon Company USA, Alumax (this plant was rated the best in the world for over 18 years), Kendall Company, and Hercules Chemical providing the foundation for his reliability and maintenance experience.

Ricky is the co-author of “Rules of Thumb for Maintenance and Reliability Engineers”, “Lean Maintenance” and “Industrial Repair, Best Maintenance Repair Practices”. Ricky also writes for different magazines during the past 20 years on technical, reliability and maintenance subjects.

Ricky holds certification as Certified Plant Maintenance Manager from the Association of Facilities Engineering as well as a Certified Maintenance and Reliability Professional from the Society for Maintenance and Reliability Professionals.

Ricky lives in Charleston, SC with his wife. Aside form spending time with his 3 children and 3 grandchildren, Ricky enjoys kayaking, fishing, hiking and archaeology.

Affiliations and Expertise

CMRP,Reliability Strategy Leader Ivara Corporation

Bruce Hawkins

Affiliations and Expertise

Life Cycle Engineering, North Charleston, SC, USA

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  • RichardSmith Tue Oct 15 2019

    Good reference

    Good reference