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Case Study: Lean Six Sigma in Maintenance Optimization

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Original date: 
Wednesday, April 12, 2017

Application of Lean Six Sigma methodology in the optimization of maintenance execution by using data and facts.    

As always, equipment maintainability plays an important role in uptime. Besides the reduction of failure rates, the quick recovery from those failures or the successful execution of scheduled activities makes a considerable difference in availability indicators. The application of Lean tools and Six Sigma analysis contributes to the improvement of maintenance execution by applying the 5 steps of Lean Six Sigma methodology (Define, Measure, Analyze, Implement and Control) and using the tools associated with them. This presentation will discuss Lean Six Sigma theory, basic principles of the methodology and case studies showing the use of tools. Case 1 will illustrate the application of Lean Six Sigma in scheduled preventive maintenance for slurry pumps operating in the oil sands industry. Case 2 will examine how the use of Six Sigma analysis reduced the corrosion rate of tubes in a bank of 12 heat exchangers shell and tube type, which heat diluted bitumen upstream of a distillation tower. Both cases emphasize the importance of using data and facts to make decisions, including front end personnel, and the sustainment of implemented solutions. 

Presented at MainTrain 2017


BoK Content Source: 
MainTrain 2017
BoK Content Type: 
Presentation Slides
Presentation Paper
Asset Management Framework Subject: 
02 Asset Management Decision Making, 2.03 Lifecycle Value Realisation, 03 Lifecycle Delivery, 3.05 Maintenance Delivery, 3.06 Reliability Engineering
Maintenance Management Framework Subject: 
01 Business & Organization Context, 1.3 Mgmt & Operational Frameworks, 05 Maintenance & Reliability Engineering, 5.1 Stats Analysis / Analytical Methods, 06 Work Management, 6.0 Work Management General, 10 Continuous Improvement, 10.3 Maintenance Management Improvements
Author Title: 
Reliability and Maintenance Engineer
Author Employer: 
Husky Energy
Author Bio: 

Gustavo Moreno is a Reliability & Maintenance engineer working for Husky Energy supporting upstream and downstream operations. Before moving to Canada on 2007, he spent 10 years working in the financial sector applying statistical and reliability concepts to improve business performance. He took the challenge to come north where initially joined Canadian Natural Resources working 4 years for the oil sand division as maintenance engineer. Trained as lean six sigma black belt, he has been able to improve reliability and maintenance performance using Lean Six Sigma tools.