Would it help to invest in a maintenance trolley? Like Lean Manufacturing, Lean Maintenance seeks to avoid waste: Wasted "activity" includes having expensive replacement parts in inventory longer than was necessary; ideally these should be ordered "just in time" for scheduled maintenance. Found inside – Page 5This Thesis advances the promotion and adoption of “Lean Thinking” and ... in the gravel road construction and maintenance processes (Project Life Cycle). “Simply put, lean means creating more value for customers with fewer resources.”. Found inside – Page 111This section explains how traditional lean thinking and principles can be applied specifically to the equipment reliability process to achieve breakthrough ... This approach is the ideal standard procedure for troubleshooting and problem solving, regardless of whether the company officially embraces Six Sigma. Another example of sporadic maintenance is a maintenance blitz. However lean can be difficult to implement in specific organisations. 02475D (Sydney). If less than 10% of maintenance activity is "repairs", you might ease back on the preventive measures. The long-term solution is either to replace the filter more frequently or to find another way to prevent dust from getting there (by adding a fan to blow the particulates in a different direction or by adding a filter to trap dust where material is being cut). 236 - 272. Add instruction sheets and find other ways to make it simple. The Maintenance Management Framework describes and reviews the concept, process and framework of modern maintenance management of complex systems; concentrating specifically on modern modelling tools (deterministic and empirical) for ... In a repair scenario, everyone feels the pressure to fix the machine so production can resume. The benefits here are the same as for the number of work orders. Determining weight of indices using Shannon entropy method. of lean thinking associated with maintenance to improve efficiency and reduce waste is through the use of total productive maintenance (TPM). However, the DMAIC approach, with appropriate quality tools, is effective in solving the widest range of problems. Lean thinking practices and techniques focus on eradicating Non Value Adding activities as well as optimizing Business Value Adding activities, such that the maximum or greatest amount of resources, attention and time is focused on the Value Adding activities. An example of a more focused problem would be "the gears seize up too often; we have to stop and make repairs". Mostafa, Sherif ORCID: 0000-0002-5708-3770, Lee, SH, Dumrak, J, Chileshe, Nicholas and Soltan, H (2015) Lean thinking for a maintenance process. Design Thinking, Lean and Agile: The 3 I’s. © WCM Consulting AB, Vaxholm, Sweden The basics were laid out in the beginning of the 20 th century. To borrow a phrase from automotive maintenance, "While you've got the hood open, you should also…". An operator might neglect to clean away dust, and unusually humid weather could change that dust into a sticky clog over a cooling fan. Invest in training them for these tasks. With a practical focus, this book encompasses the science and analytical background for improving manufacturing, control, and design. TOC is the common denominator in all the case studies presented in this book. This book opens with a chapter on what Theory of Constraints is and why it works so well in improvement efforts. Better task organization. Either prohibit bringing machines into the maintenance shop unless the replacement parts are available, or store the broken equipment safely out of the way so the technicians can repair items that do have all the parts available. The Six Sigma discipline reduces variation in order to improve quality. The latter concept is "mura" or "unevenness". A free version is available. You should pause here and take the Lean Maintenance / TPM Assessment quiz. The cost of maintaining one machine is usually much less than the cost of its breakdown, because that might shut down operations altogether. These situations are included in the above metrics, but breaking them out is important in managing the inventory of replacement parts. Lean thinking can be incorporated into maintenance activities through applying its principles and practices. Lean maintenance is a prerequisite for lean manufacturing systems. This number should be balanced against the cost of keeping a machine idle because of a parts shortage. In these Lean Quiz, we will cover questions on topics such as lean methodologies, lean methodology, leaner process, lean system, lean definition, lean business, lean practice, concept of lean, lean think, lean process, what is a lean, six sigma lean, lean on me the movie, lean six sigma, lean management, leaner business … Lean Manufacturing absolutely cannot succeed if unscheduled repairs cause widespread delays. This does not reach the Lean Manufacturing ideal of smoothly scheduling all work, but it may be a significant improvement over the ratio of maintenance to repair that your factory currently experiences. On the other hand, they will probably be stored farther away than the daily production tools. Even if you "overspend" on maintenance, Murphy's Law will sometimes cause an unexpected breakdown. This step also lays out the flow of material for efficient work processes. A friend of mine asked a great question in response to one of my recent Lean books. The ultimate goal of lean thinking is to provide perfect value to the customer through processes that generate zero waste. Lean Hospitals. How to Manage Your Lean Projects – Prioritize. context for lean thinking ¾ Ability to engage in lean thinking with respect to Wastes, and others) ¾ Increased ability to teach others about lean thinking ¾ Session Design (60-90 min.) Without a computerized maintenance management system (CMMS), how do you log, track, and report on patterns of maintenance and repair activity? The Lean Process (for a “unique” “skilled-trade” craftsman process) This repair depot had no experience with lean and in fact little experience with any serious improvement process. Let's say it is dust getting past a filter. Remember that Lean Manufacturing requires reliable machinery to keep the production processes working on time. This drives the need for accurate historical information on the intervals between failures of a critical replacement part. Found inside – Page 79The study used concepts of Lean thinking on the Value Stream Mapping tool to analyze, ... Quality Control, Safety, Maintenance and Management, pp. As well, if multiple maintenance operations can be performed during one outage, it can be more efficient than staging multiple disruptions. Too many consulting companies see "lean" as a goal in itself. This ingrains the 5S behaviours into the factory's culture and into the standard working life of each employee. 3. We determined that the best way to shake them up to understand the challenges and huge opportunities of lean were through five-day rapid improvement workshops. It uses the concepts of: Value To accomplish this, lean thinking changes the focus of management from optimizing separate technologies, assets, and vertical departments to optimizing the flow of products and services. Inefficiencies in processes. This book shows how lean thinking can be applied in practice, highlighting the key challenges and pitfalls. The authors, based at a leading centre for lean enterprise research, begin with an overview of the theory of lean thinking. Another common problem seen in the work of facilities management groups is the lack of proper organization in the handling of tasks. This may reveal "the gears seize up every two or three months". Foremost is the fact that unscheduled downtime in a Lean Manufacturing shop affects more than just one machine: downtime can disrupt the whole factory. However, this article provides advice on what any Lean Maintenance program needs and should accomplish. ... the process flow is improved. It is also excellent at ensuring tools are stored in the right places. It is often a first step towards Lean Manufacturing and other production methodologies. Lean Maintenance has the goal to make scheduled maintenance about 80% of the crew's labour time. The operator might not be trained to perform all the necessary steps. Reducing turnaround time for overhauling an airplane is critical when the goals include returning it quickly to the field and meeting budget targets. Numeric-control or computer-guided machines may have program bugs. What is meant by “Lean Thinking” and where can Lean be applied? Also use that repair history as a guide to what should be tested in order to implement condition-based maintenance. Most factories see a significant reduction in overall cost, because unscheduled repairs are extremely expensive due to lost productivity. It is possible, in fact, to implement Lean Maintenance without formally adopting any of the other disciplines. Do not assume that each needs the same schedule. See the article about Preventive Maintenance] for more background. In our first post of this series, we discussed how to avoid void work overload using a project management board. This may be the most obvious benefit of scheduled maintenance versus unscheduled repairs. Baluch, Abdullah, and Mohtar (2012) Here are more details on these requirements: This may be the largest hurdle in planning a Lean Maintenance program. Applying lean thinking to the maintenance of train bogies. Ongoing evaluation is important to the success of a Lean Maintenance program. This approach can reduce the waste of storing an excessive inventory of replacement parts for too long, as well as the waste of time to procure out-of-stock replacement parts. ¾ Part II: Key Concept or Principle Defined and Explained (5-7 min.) Many maintenance gurus estimate that even fewer breakdowns indicates that too much time and effort are being spent on maintenance. In many other industries, maintenance is not often management's first area of concern when looking to improve productivity and profitability. Lean maintenance is a management strategy that aims to apply lean principles and goals to physical asset management. Supported by an integrated route map and comprehensive benchmark data, this book enables engineers, technicians and managers to explore this potent technique fully. * Unites the concepts of world-class manufacturing, Lean and TPM. * Shows ... Design Thinking, Agile and Lean are ways of innovating that focus on building products and services that create customer value and take the risk out of development and delivery processes. As well, many machines begin producing defective, or at least, less-than-ideal products, as they near their next maintenance date. Lean Manufacturing seeks to cut out three types of waste: Processes that do not add value for the customer. The beauty of lean thinking is that is can be applied to any industry or business model. Whether you work in software development, manufacturing systems, or industrial engineering, you can apply the principles of lean to your operations. It benefits your customers, your team members, and your shareholders (if you have them). 5S also helps if rarely-used tools are misplaced or forgotten. This article reports on the Lean tools that can be typical supply chain management of a rolling stock service organisation was used for … It’s a business philosophy that can be applied to every aspect of an organization and drive better results. The training should include "how to write up a work order" so it communicates the situation as effectively as possible. This inventory should decrease over time as parts are used, and only re-ordered in time for the next usage. The 5S program is very useful if dirt, dust or other contaminants lead to equipment breakdown. Other books provide snapshots of companies before and after lean was implemented. This is the first book to provide technical descriptions of successful solutions and performance improvements. Found inside – Page 2XNC WTER Wine Starting down the Lean road MOIS By Brig . Gen. ... and Lean tion system . Now you're thinking , phase maintenance process . In a Thinking . 4. This leaves some time for emergency repairs but the crew still is busy throughout the shift. Many people are already familiar with its applications in the world of manufacturing and engineering. One example of making maintenance easy is an automobile's dipstick: bright yellow handle like the other two things the driver is encouraged to check; only one place to put it in; has markings for "too low", "in range" and "overfull". 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 ... Many maintenance managers aim to keep their maintenance crew scheduled to about an 80% load. The question is very important: what did it cost to be out-of-stock of a critical part? Create a simple Autonomous Maintenance checklist for all inspection, set point, lubrication, and other operator-controlled maintenance tasks (creating Standardized Work for the Autonomous Maintenance process). The four most common root causes for machines to break down are: operator error; programming error (for computer-controlled tools); inadequate maintenance; and environmental causes. A simple example would be trying to drill too quickly for the type of material. It benefits your customers, your team members, and your shareholders (if you have them). Two requirements for condition-based maintenance are: measure the critical indicators that will change before the machine fails; and measure with enough lead time to schedule the maintenance and procure any required parts. Applying Lean Thinking to Software Development. But each method has a specific focus and combination of tools, as well as suitability for different projects. Make a separate plan for maintaining each model of machine. However, the corporate culture espoused by "Lean" works well for both the manufacturing and maintenance operations. For Lean Maintenance, the equivalent "waste" concepts to be avoided are: Many of the gurus advocating Lean Maintenance point to blindly scheduled maintenance as a waste, especially if it involves replacing expensive components or incurring high labour costs or lengthy downtime. Inefficient activities may refer to delays while performing maintenance, such as chasing around for tools or replacement parts. This collaborative thinking will also extend to your suppliers as well, who will want to use lean themselves to generate their own improvements. Found inside – Page iThis book provides a new challenge. It arises from the work of the Lean Aerospace Initiative at MIT and provides a new agenda and bold vision for the aerospace industry to take it out of crisis. Get copies for your controller and all senior managers...this book lays it all out. To conclude, the two "Lean" approaches do work well together. Found inside – Page 255How to Apply Lean Thinking to Your Supply Management Processes Paul Myerson. M Maintenance, repair and operating (MRO), 131 Marginal pricing, ... This is "condition-based maintenance", which defers maintenance until there truly is a need. At this point, implementing the solution may require changes in the engineering of the equipment or in the behavior of the operator. Operating speeds and temperatures are normal until just before the gears seize, at which time it slows down and heats up. It can be time-consuming, especially in the analysis and final control steps. As an example: let's say that lubricating oil begins to break down, triggering an oil change as maintenance. Found inside – Page 25625(6), 937–944 (2009) Crespo Márquez, A.: The maintenance management framework. ... J., Chileshe, N., Soltan, H.: Lean thinking for a maintenance process. Found inside – Page 3processing times, variable demand, and process interruption due to maintenance issues. ... A widely referenced book, Lean Thinking: Banish Waste and ... Written for anyone in a leadership position, this book takes readers on a journey from uncovering waste, designing projects to address the waste, selling the projects to management, and delivering the projects. No excessive wear is found. lean must be a change in company culture and thus must become a way of thinking for the company. Generally consultants advise integrating Lean Maintenance with the production disciplines, such as Six Sigma or 5S, already implemented in your factory. This metric is similar to "downtime" in the previous section. The never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. A lot of dust is in the air around this machine, and settles on everything. Lean thinking is a way of thinking about an activity and seeing the waste inadvertently generated by the way the process is organized. This research proposes a new structure for LM process based on a systematic literature review of a significant number of related articles that were published on LM. The beauty of lean thinking is that is can be applied to any industry or business model. The same principle should apply to replacement parts: purchase them "just in time" for the next maintenance activity, rather than just after the last one. Would better tools help the employees do a better job? The maintenance process shares significant operating costs in an organisation. What I want to offer is a holistic view where the current situation and goals are clear and where the tools from lean and other effective methods are selected and implemented thoughtfully. What about training session from the manufacturer? ¾ Part I: Introduction and Learning Objectives (1-2 min.) Do the gears seize up anyway in three months? Lean Manufacturing recognizes that working at high speeds and under pressure often lead to errors. Good planning also ensures that the right parts and tools are available, along with people who have the appropriate skills. Whether you make your schedule based on past repair history or, preferably, using condition-based testing, scheduling has several benefits over repairing after breakdowns: The target is to schedule about 90% of the tasks. Then, divide those value streams into work cells for each assembly. Found insideAt the same time, companies find themselves with declining customer loyalty & greater challenges in fulfilling orders. This text offers solutions to these problems. On the production side, a new customer order may trigger purchasing new raw material. A clear action item for the maintenance team is to ensure that tools and replacement parts are stored where they are convenient for the tasks. Hearing about the increasing pressures and challenges affecting the field service supply chain, and the different ways organisations are seeking to address them, triggered a train of thought in my mind around the power of lean thinking. Found inside" This is a question many executives and managers are asking. Articles. Many argue that so-called “event lean” is the reason that many companies fall short at creating a lean … If an employee's work day is divided between being idle for five minutes and working frantically for ten, then her workload should be smoothed out so she can work steadily all day. These theories are tried and tested before deciding on a solution. Are there similarities and synergies between Lean Manufacturing and Lean Maintenance? It is, indeed, possible to set a maintenance schedule so that the schedule pulls the maintenance activity. Here we get some selected projects running and begin to create an environment in which the principles of Lean are included into the everyday operation. One aspect of evaluating a maintenance program is to check for an improvement in customer retention due to timely deliveries. Lean Software Development: An Agile Toolkit Adapting agile practices to your development organization Uncovering and eradicating waste throughout the software development lifecycle Practical techniques for every development manager, project ... Recall that the primary concept for Lean Manufacturing is to reduce several types of waste. Lean thinking can be incorporated into maintenance activities through applying its principles and practices/tools. These are too expensive to keep in stock, but highly valuable in that they are needed to keep the machine running. ISSN 2169-3277. Replacement parts are included in the search for misplaced or out-dated items. Over the years, I have helped clients such as NCC, ABB, and Kopparbergs Brewery approach a world-class production. One of the difficulties is deciding which of the many lean tools to apply and when to apply them. The goal is to see this number trend upward. Found insideWinner of a Shingo Research and Professional Publication AwardThe new edition of this Shingo Prize-winning bestseller provides critical insights and approaches to make any Lean transformation an ongoing success. With a focus on condition-based scheduling for maintenance and a reduction in the need for unscheduled repairs, Lean Maintenance does reduce inefficiencies. Here is how they are trying to get there. As you acquire data, you need to evaluate the effectiveness of the Lean Maintenance program, by comparing various metrics between the "before" and "after" time periods: Of course, you will add the cost of planning and implementing Lean Maintenance to the "cost" ledger. Found inside – Page 170Maintenance Work Maintenance work made up the bulk of the work after hours for the more junior of the medical officers on call. The maintenance tasks were ... Scope of topics discussed in this book covers also pollution prevention, energy efficiency. The authors describe problems of information management in complex systems Lean Maintenance is a key ingredient to a successful Lean Manufacturing environment. In the daily work of a company, routines that maintain organization and orderliness are essential to a smooth and efficient flow of activities. Post a schedule for the maintenance activities, with boxes for the employee to initial and date, beside the instruction sheet. caused by the non-value added (NVA) activities or wastes within the entire maintenance process. The Six Sigma approach can be overwhelming in the analysis step. With a successful accomplishment of the proposed scheme, the performance of a maintenance department can create more improvement opportunities over time to reach the maintenance excellence status. The performance parameters of the machines are more readily available than the likelihood of breakdowns for those machines. In a Lean Manufacturing shop, where work-in-process should flow smoothly from machine to machine, an unscheduled repair could bring the entire factory to a halt. Historically, Lean thinking has limited applications in the maintenance environment (that is, a non-manufacturing environment). The costs of unscheduled downtime are enormous in such a factory. 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Over the years, I have helped clients such as NCC, ABB, and your shareholders if. Regardless of whether the company officially embraces Six Sigma the production disciplines, such as chasing around tools. Maintenance of train bogies clients such as Six Sigma is usually much than! Lean themselves to generate their own improvements for efficient work processes here and take the lean road MOIS Brig! On time improvement in customer retention due to timely deliveries find other ways to make it.. In managing the inventory of replacement parts are used, and design Six Sigma 5S! As Six Sigma, `` While you 've got the hood open, should.
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