Implementing Lean Maintenance
  • 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 Maintenance 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:

  1. Effective Maintenance Execution by highlighting non value adding Maintenance routines and opportunities to enhance production and maintenance asset care workflows,
  2. Robust Process Stability by targeting problem hot spots, early problem detection and problem prevention routines,
  3. Enhanced Process Resilience by dealing with sources of accelerated wear including contamination and human error,
  4. Improved Flexibility of resources using standards and visual management to systemise routine tasks to make it easier to achieve core competencies,
  5. 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.

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