October 21, 2020, 4:13 am

Lean Maintenance

We Optimised our Preventive Maintenance without realising it

 It is sometimes interesting to reflect on our own exposure to maintenance when it is overlaid with current thinking and methodologies for best practice maintenance.

In the 1990’s, off highway dump trucks were serviced every 250 hours. This would involve bringing the truck into the workshop for about a shift. We would change the engine oil and carry out other OEM recommended tasks. On top of this we would have carried out a host of other inspections and checks. These would cover everything from hose inspections and electrical checks to our own bespoke checks that had been implemented over a period of time.

Fast forward to the current day and we service our trucks at 500 hour intervals. This has been facilitated by the extension of the oil change interval from 250 hours to 500 hours. So now, instead of the trucks coming into the workshop every 250 hours for a service and the associated inspection, they come in every 500 hours.

So, what has happened to all the inspections and maintenance tasks that were being carried out every 250 hours in the 1990’s? How have we saved a shift of downtime every 250 operating hours? Did we not need to be doing all those checks every 250 hours? In a crude sense, what most of us did was implement the results of a PMO study without realising it.

 

4 Tips for Maintenance Productivity Improvement

In this short video we give 4 practical tips that can help you to improve the productivity of your maintenance function.

 

 

 

 

5 Keys to Lean Maintenance & Improving Maintenance Productivity – Part 6 – Think Holistically

In the first in this series of articles, we discussed the benefits that leading organisations enjoy when they have high levels of maintenance productivity, and outlined methods for achieving this.  Since then, we’ve been working through the proposed methods and examining how each can be used to eliminate waste to deliver Lean Maintenance with improved productivity. In this article, we will tackle the final topic on this list, 'Think Holistically.'

 

5 Keys to Lean Maintenance and Improving Maintenance Productivity - Part 5 - Environment for Success

In the first in this series of articles, we mentioned that any improvement process is headed for failure without the buy-in and support of all those involved; it is imperative that the leadership and culture is focussed on being proactive rather than reactive, and is performance driven.  In addition, we stated that the development and implementation of a 'balanced scorecard' of Key Performance Indicators (KPIs) and the support and communication from management are the keys to delivering improvement. In this article we will expand on these thoughts.

 

5 Keys to Lean Maintenance and Improving Maintenance Productivity - Part 4 - Continuous Improvement

If your Maintenance function is already doing the right work, and you are doing the work right, there are primarily three areas in which continuous improvement can further improve Maintenance Productivity. These are:

  • Eliminating the wastes which prevent Maintenance work from being performed efficiently,
  • Continuously improving the Preventive and Predictive Maintenance program, and
  • Eliminating the defects which cause the need for Maintenance work
 

5 Keys to Lean Maintenance and Improving Maintenance Productivity - Part 3 - Doing the Work Right

In this article, we will tackle the second of the 5 keys to Lean Maintenance and Maintenance Productivity Improvement - doing the work right.

“Insanity: doing the same thing over and over again and expecting different results.” Albert Einstein

This is the third in a series of articles on improving Maintenance Productivity through the use of Lean Maintenance techniques.

 

5 Keys to Lean Maintenance and Improving Maintenance Productivity - Part 2 - Doing the Right Work

In the first in this series of articles, we discussed the benefits that leading organisations enjoy when they have high levels of maintenance productivity, and outlined five ways in which maintenance productivity may be improved.  These were:

  1. Doing the right work
  2. Doing the work right
  3. Focusing on continuous improvement
  4. Creating an environment for success
  5. Thinking holistically

In this article, we will tackle the first of these 5 keys to Lean Maintenance and Maintenance Productivity Improvement.

 

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