"The 10 Steps to Lean Production; Step Four: Reliability Through Integrating Preventive Maintenance"

Steven Hunter

FDM

January 2004, pp. 30-33

In this continuing series of articles, the author this time explores the role of Maintenance in Lean Production.

The key point of this article is that "An essential element in the lean manufacturing system is system reliability. Lean systems have serial, linked processes, and by definition, do not have redundant components or duplicated machinery. Every component must operate properly every time."

In the Lean Production system, operators "are required to become aware of their equipment and its routine problems, such as process drift, loss of stability or loss of accuracy…workers carry out low level preventive maintenance tasks that take little effort or technical expertise. They include checking fluid levels, process alignment and other low-tech tasks."

The Maintenance Department carries out the maintenance tasks that are beyond the expertise of operators. These include process overhaul, replacing computer boards, and other high-level tasks.

The article also briefly discusses the 5S principles of workplace housekeeping (Sorting, Simplifying, Systematic Cleaning, Standardizing and Sustaining), as well as Nakajima's 5 pillars for integrated preventive maintenance:

1. Eliminate the six production losses
2. Develop an autonomous maintenance program involving workers in daily equipment maintenance
3. Develop a company maintenance policy
4. Increase operator and maintenance personnel skill
5. Develop an equipment management program, including a record of machine and tool use that notes how much they were used and who used them.

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