Lean Maintenance Strategy Workshop

Learn how apply the Lean Maintenance Road Map to build on existing good practices and improve:

• Maintenance execution through standard work that:
  
  • Removes the causes of accelerated wear and human error.
  • Improves working methods, speeds up skill development and simplifies spares management.
• Process optimisation using Lean Workflow Management, Data Analysis and Problem Prevention tools to
  • Stabilise and extend component life
  • Improve resilience to shifts in demand

• Project management of shutdowns or the introduction of new equipment, systems, products and services.

The content includes lessons from well known and award winning organisations to explain how engaging Maintenance within a Lean programme can deliver as much as 50% more in terms of year on year gains.

Through the workshop delegates will:

• Learn how current maintenance practices compare with best in class maintenance standards
• Understand where there are gaps and how that impacts on maintenance value
• Know how to resolve those gaps and justify actions to do so
• Be able to develop a forward programme to deliver the gains from adopting a Lean Maintenance approach.

Delegates will take away a comprehensive workbook containing briefing notes and supporting templates so that they can carry out the review process in the future.

Engineering and Maintenance leaders, Lean champions, Facilitators and First Line Managers and key maintenance personnel with an interest in increasing their understanding of how to release the full potential of the maintenance function.

Assessing Current Status and Future Demands

• Introductions and programme overview
• Assessing maintenance processes
• The role of maintenance (Preventive, Corrective, Optimise)
• Measuring equipment and departmental performance
• Digitisation and the changing landscape of maintenance engineering

Lean Maintenance Simulation

• Team based improvement glide path comparison:
  
  • Traditional Maintenance
  • Lean Maintenance 

Managing Maintenance Value

• Maintenance value for money
  
  • Loss tree analysis
  • Maintenance impact on Manufacturing Cost and Value
• Management and leadership tools to secure improvement
  
  • Cultural drivers and engagement
• Gap Analysis
  
  • Setting equipment condition and maintenance standards
  • Accountabilities
  • Skill Development
  • Learning and compliance

Developing Maintenance Standards

• Setting standards and standard work
• Stabilising performance
• Focussed improvement

Delivering Focussed Improvement

• The annual maintenance plan
• Maintenance controls
  
  • Daily management, data and analysis
• Recording, observation and problem prevention
• Sharing best practice and education

Action Planning

• Developing a maintenance improvement programme
• Next 90-day action plan

Workshop Leader - Dennis McCarthy

An author of 2 books on CI, Dennis' career includes positions in both general management and consultancy. Described by one senior international manager as a true "Sensei of Change" he has guided continuous improvement programmes ranging in size from small single site applications to company-wide multi-site transformation programmes.

This has included support for well-respected and award winning companies such as 3M, Ford, General Motors, GE, IKEA, Heineken and Johnson Matthey across Europe, India, USA, China and Japan.