Day 1 Lean maintenance and where it fits in, problem solving

• History of Lean Maintenance
• Techniques for continuous improvement including inputs to maintenance.
  • Looking at the inputs to maintenance for areas to make more efficient
  • Looking at the outputs to optimize the use of the resource
• How Lean Maintenance is related to Lean Manufacturing?
  • Lean maintenance provides a Lean service to operations
  • Many of the tools can be brought over (types of observation, 8 losses, etc.)
• How to see waste in your operation
• The role of Lean Maintenance
  • Be Lean to survive global competition
  • Be Lean to be a preferred employer
  • Have faster reaction times to shifts in the marketplace

Specific Lean Strategies

• Lean TPM
  • What is it?
  • How can we take advantage of it?
  • Design Lean tasks
• Lean Work Orders
  • Better machine histories
  • Training for mechanics, operations and planners
  • Examples of Lean and Fat work orders
  • Specific techniques to reduce fat from your use of work orders
• How to use your CMMS in a Lean way
  • Take advantage of your data
  • Where to get data to support cost saving plans.
  • Exercise in developing a Lean CMMS protocol
• Recreating your PM system to be Lean
  • Where is the waste in PM
  • Exercise in PM and Lean maintenance
• Using technology for PdM inspection and for Lean Maintenance
• How to plan and schedule maintenance jobs for Lean execution
  • Exercise in Lean Planning
• Attack fat in the maintenance warehouse
  • Techniques to cut costs of acquisition
  • Techniques to cut costs of ownership
  • Exercise in Lean Inventory approaches
• Is safety Lean?
• The goal: a Lean worker

Day 2 Finding waste and the development of the Lean Project

• Brainstorming sessions specifically designed to uncover waste.
• Where to focus initial attention
• Use this Priority system to insure actionable projects.
• Where to look for the 'low hanging fruit'.
• Massive Lean Maintenance Project development
  • Groups set priority for each idea based on proprietary measures.
  • Groups develop list of projects in priority order
  • Forms are offered to help groups refine and write-up one idea
  • Rigorous formats are employed to insure projects are thought through, and different aspects are reviewed.
  • How to conduct a cost analysis on a money saving project.
  • How to get these projects done in the real world.
• Assign management mentor that will provide:
  • Money that was budgeted,
  • Run interference,
  • Get supplies, help, faith, access to asset and resources, whatever else is needed
• Present a Lean Project
• How to write success stories. Pass stories on to management