- Details
- Parent Category: Courses
- Category: Ratchet Up Performance
- Dates: 3 day training workshop
- Location: In Company Course
- Cost: £4500 up to 10 Delegates
Enhancing Maintenance Value
Lean Manufacturing can only deliver high levels of added value when equipment, processes and tooling are in peak condition. To do that Lean Maintenance provides the toolbox to stabilise and extend component life so that operational assets can produce higher levels of added value for longer. That starts with the evolution of maintenance workflows to systematically reduce waste and non value adding activities, releasing time to focus on enhancing process effectiveness, resilience and flexibility. That includes adapting work routines to take advantage of advances in technology and digitisation.
This 3-day workshop leads delegates through the theory and practices of how Lean theory applies to Maintenance routines. Delegates work in teams to apply Lean Maintenance principles to up to 3 assets to create examples of:
- Lean Asset Care covering preventive maintenance, condition based inspection and servicing routines,
- Lean Execution covering standardisation, systemised workflows, use of data performance management and CMMS
- Lean TPM Centre of Excellence covering skill development, performance management, Focussed improvement and engagement.
The lessons from the practical activities are used to illustrate how following the Lean Maintenance road map can deliver:
- Systemised asset care routines
- Improved maintainability and compliance,
- Increased stability of component life.
- Maintenance planning, scheduling and work control,
- Problem resolution and process optimisation,
- Information management and knowledge sharing.
- Learning and knowledge sharing
- Accelerated wear and recurring failures,
- Engagement with continuous improvement.
The lessons from the practical activities are used to illustrate how following the Lean Maintenance road map can deliver:
- Effective Maintenance Execution by highlighting non value adding Maintenance routines and opportunities to enhance production and maintenance asset care workflows,
- Robust Process Stability by targeting problem hot spots, early problem detection and problem prevention routines,
- Enhanced Process Resilience by dealing with sources of accelerated wear including contamination and human error,
- Improved Flexibility of resources using standards and visual management to systemise routine tasks to make it easier to achieve core competencies,
- Reduced Manufacturing Costs by systematically resolving the causes of reactive maintenance to stabilise and extend component life.
Deliverables include the development of a bespoke Lean Maintenance route map to release maintenance resource to improve asset effectiveness. A transition from the traditional maintenance outlook of preventing downtime to one of preventing defects to deliver the full value adding potential of the maintenance function.
In addition to the above benefits, incorporating Lean Maintenance within a Lean, TPM or Six Sigma programme has been shown to increase annualised gains by as much as 50%.
Overview
This workshop provides a step by step guide to Lean Maintenance practices capable of delivering high levels of reliability and of releasing the value adding capability of the maintenance function to:
- Systematically reduce recurring breakdowns and increase equipment effectiveness.
- Increase machine reliability, optimise maintenance schedules and release maintainer resource to undertake value adding engineering improvements.
- Develop maintenance skills and site preventive maintenance capability.
- Improve data driven decision making through better use of CMMS systems and processes.
- Establish a common continuous improvement "mind-set" across all operational functions.
The workshop content includes an overview of improvement tactics such as TPM, RCM, CBM and Quality Maintenance and Computer Maintenance Management Systems (CMMS).
Delegates will use a comprehensive workbook containing briefing notes and supporting templates to assess current practices against Lean Maintenance benchmarks for best practice.
Who should attend ?
The course is designed to mobilise maintenance improvement team activities and support the evolution of best practice to achieve high levels of reliability with minimum effort. The content is relevant to:
- Engineering and Maintenance Leaders,
- Lean Champions,
- Facilitators and Change Agents
- First Line Managers
- Key maintenance personnel with an interest in increasing their understanding of how to release the full potential of the maintenance function.
The course is also recommended for those following the DAK Leader Guide to reduce minor stops and quality defects.
Workshop Agenda
Day 1:
- Introduction:
- Learning goals and agenda.
- The power of Lean/Systems Thinking.
- Lean Manufacturing and Lean Maintenance.
- Lean Maintenance Added Value:
- Preventive, Corrective, Process Quality,
- Industry 4.0 and the changing landscape of maintenance engineering.
- Lean Maintenance Added Value:
- Lean Maintenance Process
- Lean Asset.
- Lean Execution.
- Lean Centre of Excellence
- Mini Pilot Session 1: Lean Asset
- Establishing Basic condition standards:
- Condition appraisal and refurbishment planning,
- Asset Care Standards:
- Prevention,
- Inspection,
- Servicing.
- Dealing with accelerated wear hot spots:
- Contamination,
- Human error.
- Skill development and compliance.
- Establishing Basic condition standards:
Day 2
- Mini Pilot Session 2: Lean Execution
- Stores:
- Planning, scheduling and work control,
- Lubrication,
- Work in progress.
- Performance Management:
- Cultural drivers and engagement,
- Early Problem Detection,
- Trouble shooting algorithms.
- Use of data:
- Spares management,
- Recording, observation and problem prevention,
- CMMS.
- Mini Pilot Session 3: Lean TPM Centre of Excellence
- Standardising best practice:
- Core and Intermediate task characterisation,
- Visual management,
- Problem Prevention.
- Systemising work routines:
- Enhancing workflow,
- Improving flexibility,
- Stoppage analysis and resolution.
Day 3
- Feedback.
- Mini Pilot Session 4: Lean Maintenance
- Lean Maintenance Maturity Assessment.
- Action Planning
- 3-5 years.
- 12 month goals.
- 90-day action plan.
- Review of the workshop.
Course Leader
The workshop will be led by Dennis McCarthy. Dennis has supported Total Productive Maintenance, Lean Thinking and Continuous Improvement programmes ranging in size from small single site applications to company-wide multi-site transformation programmes in Europe, USA, India and China. This has included support for well- respected and award winning companies such as 3M, Ford, General Motors, GE, RHM and Dow Corning.
Dennis co-authored Lean TPM a blueprint for change”, with Nick Rich of Cardiff University Business School. Published by Butterworth Heinemann. He also wrote Early Equipment Management, “Continuous improvement for projects” published by Productivity Press. Engineering aspects from both books feature in this course.
