Lean Maintenance is a relatively new term, coined in the last decade of the twentieth century, but the principles are well established in Total Productive Maintenance (TPM). Lean Maintenance taking its lead from Lean Manufacturing applies some new techniques to TPM concepts to render a more structured implementation path. To reduce costs and improve production, most large manufacturing and process companies that have embraced the Lean Enterprise concept have taken an approach of building all of the systems and infrastructure throughout the organization. The result of this traditional approach has been erratic implementation efforts that often stall-out, or are terminated, before the benefits come. Plants can accelerate their improvements with much lower risk through the elimination of the defects that create work and impede production efficiency. Optimizing the maintenance function first will both increase maintenance time available to do further improvements and will reduce the defects that cause production downtime. Thus, cost reduction and improved production are immediate results from establishing Lean maintenance operations as the first step in the overall Lean Enterprise transformation. Lean Maintenance is intended to be a stand-alone teaching text that provides the student with all the terminology (defined), all of the Lean Implementation Processes including techniques for getting the most from the application of each process and all of the planning and sequencing requirements for proceeding with the Lean Maintenance Transformation journey including methodologies and background information. At the same time, or rather after it has served its purpose as a teaching text, Lean Maintenance is intended to be a quick reference volume to keep with you during your actual journey through the Lean Transformation. We have tried, through the extensive use of charts, tables, and checklists, to make any single piece of information, as well as the sum of all of the information, simple to locate and effortless to understand.
Upon successful completion of this course, the delegates will be able to:
Day 1
Common Ground
The History and Evolution of Lean:
Lean Manufacturing and Lean Maintenance:
Governing Principles: What Is Lean and What Is Not:
Day 2
Relationships in the Lean Environment
Goals and Objectives
The Primary Goals and Objectives of Manufacturing
Sales
Integrating Lean Goals with Maintenance Goals
Day 3
The Need For, And Gaining, Commitment
Measuring Progress
Total Productive Maintenance (TPM)
TPM (Fine-Tuned) Is Lean Maintenance
Day 4
Fine-Tuning TPM Using Reliability Centered Maintenance (RCM)
Pre-Planning for Lean Maintenance
Gaining Knowledge/Imparting Knowledge
The Transformation Roadmap
Lean Maintenance Transformation Kick-off Meeting
Phase 1: Developing the POA&M and the Master Plan
Launching the Master Plan (POA&M)
The Sequence of Events
Day 5
Mobilizing and Expanding the Lean Transformation
Mobilizing Lean in the Maintenance Organization (Phase 4)
Expanding the Lean Maintenance Transformation (Phase 5)
Lean Expansion Major Efforts
Sustaining Lean—Long Term Execution
Sustaining Continuous Improvement (Phase 6)
This course is designed to accommodate the needs of directors, managers, superintendents, supervisors, engineers, planners, team leaders, controllers and coordinators who are involved in maintenance, plant/project management, shutdowns and turnarounds, engineering, reliability and asset management.