Lean Maintenance (eBook)

Cover 1
Contents 7
Preface 11
1 Common Ground 13
1.1 THE HISTORY AND EVOLUTION OF LEAN 13
1.1.1 Manufacturing Evolves 13
1.1.2 The Influence of Henry Ford 15
1.1.2.1 Waste„The Nemesis of Henry Ford 15
1.1.2.2 Ford’s Influence on Japanese Manufacturing 18
1.1.2 Japan’s Refinement of Ford’s Mass Production System 19
1.1.2.1 The Kaizen Process 21
1.2 LEAN MANUFACTURING AND LEAN MAINTENANCE 22
1.2.1 Elements of Lean Manufacturing 22
1.2.1.1 Lean Thinking and the Lean Organization 24
1.2.1.2 The Role of Maintenance 25
1.3 GOVERNING PRINCIPLES: WHAT IS LEAN AND WHAT IS NOT 26
1.3.1 What Lean Manufacturing Isn’t 26
1.3.2 What Lean Manufacturing Is 28
1.4 RELATIONSHIPS IN THE LEAN ENVIRONMENT 28
1.4.1 Information Integration in the Lean Organization 28
1.5 SUMMARY OF LEAN CONCEPTS 29
2 Goals and Objectives 32
2.1 THE PRIMARY GOALS AND OBJECTIVES OF MANUFACTURING 32
2.1.1 Sales 33
2.1.2 Production 34
2.1.3 The Manufacturing Budget 34
2.1.3.1 Budget Elements 35
2.1.3.2 Controlling Costs 35
2.1.3.3 Optimizing Maintenance as a Cost Control Measure 39
2.1.3.4 CPU„The Bottom Line 41
2.1.4 Growth and Continuous Improvement 43
2.2 INTEGRATING LEAN GOALS WITH MAINTENANCE GOALS 43
2.2.1 Maintenance Objectives and Goals 43
2.2.1.1 Maintenance Objectives 44
2.2.1.2 Maintenance Goals 45
2.3 THE NEED FOR, AND GAINING, COMMITMENT 47
2.3.1 The First Step: Top Level Management Buy-in 47
2.3.1.1 The Good 48
2.3.1.2 The Bad and the Ugly 48
2.3.2 Selling at Each Level 49
2.4 MEASURING PROGRESS 50
2.4.1 Metrics 50
2.4.2 Selecting Performance Indicators and Key Performance Indicators 53
2.4.3 Maintain and Publish the 65
3 Total Productive Maintenance (TPM) 67
3.1 TPM (FINE-TUNED) IS LEAN MAINTENANCE 67
3.1.1 Elements and Characteristics 67
3.1.1.1 Organization 71
3.1.1.2 Work Flow and the Work Order 76
3.1.1.3 Support Functions 79
3.1.2 Best Maintenance Practices and Maintenance Excellence 79
3.1.3 Maintenance Skills Training & Qualification
3.1.4 MRO Storeroom 86
3.1.5 Planning and Scheduling 88
3.1.6 CMMS (Computerized Management Maintenance System) 90
3.1.7 Maintenance Documentation 96
3.1.8 Maintenance Engineering 103
3.2 FINE-TUNING TPM USING RELIABILITY CENTERED MAINTENANCE (RCM) 103
3.2.1 What RCM Accomplishes 104
3.2.1.1 The Origins of RCM 104
3.2.1.2 Properties of RCM: 105
3.2.2 Integrating RCM and TPM 107
3.2.2.1 Equipment Criticality and Maintenance Priorities 108
3.2.2.2 Reliability Engineering 108
4 Pre-Planning for Lean Maintenance 117
4.1 GAINING KNOWLEDGE/IMPARTING KNOWLEDGE 117
4.1.1 Selecting the Lean Maintenance Project Manager 117
4.1.1.1 Necessary Attributes of Lean Maintenance PM 118
4.1.1.2 Lean PM Duties and Responsibilities 118
4.1.2 What You (the Lean PM) Should Know 119
4.1.3 Who Else and How to Familiarize Support Activities 125
4.1.3.1 Educating the Project Team 125
4.2 THE TRANSFORMATION ROADMAP 126
4.3 LEAN MAINTENANCE TRANSFORMATION KICK-OFF MEETING 133
4.4 PHASE 1: DEVELOPING THE POA& M AND THE MASTER PLAN
5 Launching the Master Plan (POA& M)
5.1 THE SEQUENCE OF EVENTS 137
5.1.1 Phase 2„The Lean Preparation Phase (Education) 138
5.1.1.1 5-S (Visual) 138
5.1.1.2 Standardized Work Flow 140
5.1.1.3 Value Stream Mapping 142
5.1.1.4 Just-in-Time (JIT) and Kanban PullŽ System 144
5.1.1.5 Jidoka (Quality at the Source)„Poka Yoke (Mistake Proofing) 145
5.1.1.6 Shewhart Cycle (PDSA) 145
5.1.2 Lean Pilot (Phase 3) 147
5.1.2.1 Selecting the Project 147
5.1.2.2 The Pilot Kaizen Events 150
6 Mobilizing and Expanding the Lean Transformation 153
6.1 MOBILIZING LEAN IN THE MAINTENANCE ORGANIZATION (PHASE 4) 153
6.1.1 Teams and Activities in Phase 4 154
6.1.1.1 5-S and Visual Cues Campaigns 156
6.1.1.2 Autonomous Operator Maintenance 157
6.1.1.3 Action Team Leader Knowledge Sharing 159
6.1.1.4 Completing Maintenance Mobilization 160
6.1.2 Mobilization Brings Change 161
6.1.2.1 New Roles for Management and Supervision 161
6.1.2.2 A Change of Organizational Focus 161
6.2 EXPANDING THE LEAN MAINTENANCE TRANSFORMATION (Phase 5) 163
6.2.1 Lean Expansion Major Efforts 164
6.2.1.1 Expanding to Purchasing 164
6.2.1.2 Expansion to Maintenance Engineering 167
6.2.1.3 Expansion to IT Department 170
7 Sustaining Lean„ Long-Term Execution 172
7.1 SUSTAINING CONTINUOUS IMPROVEMENT (PHASE 6) 172
7.1.1 Applying the Tools 173
7.1.1.1 Optimizing Maintenance Using Lean Tools 174
7.1.1.2 The Sustaining Environment and Activities 187
Appendix A Checklists and Forms 191
Appendix B Documentation Examples 225
Appendix C Articles of Interest 231
Glossary 277
Index 283