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PM Optimization: Integrating Lean into your Maintenance Strategy

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Original date: 
Saturday, February 4, 2017
Preventive Maintenance (PM) Optimization is often thought of as an activity to improve the effectiveness of the maintenance strategy, looking at the activities in the PM routine and matching them with known failure modes. While this is the first step to improving any maintenance strategy, it is just a beginning. In order for an organization to achieve its highest performance, they not only need to do the right maintenance, but they also need to do it efficiently.This is where PM Optimization can unlock the hidden potential. When PM Optimization is combined with known and accepted Lean techniques, the efficiency of maintenance is truly unlocked. When performing PM Optimization, the team should be aware of the 8 types of waste: (1) Defects, (2) Overproduction, (3) Waiting, (4) Not utilizing talent, (5) Transportation, (6) Inventory excess, (7) Motion waste, and (8) Excess processing. Once the team is aware of the waste, there needs to be an unrelenting focus on eliminating the waste and minimizing planned downtime. To eliminate the waste, the team uses various Lean tools, such as SMED, 5s, and Visual Factory. When the 8 types of waste are targeted, the amount of planned downtime goes down, allowing higher levels of asset utilization. Presented at MainTrain 2017
BoK Content Source: 
MainTrain 2017
BoK Content Type: 
Presentation Slides
Presentation Paper
Asset Management Framework Subject: 
03 Lifecycle Delivery, 3.05 Maintenance Delivery
Maintenance Management Framework Subject: 
04 Tools and Tactics, 4.2 Preventive Maint. Optimization, 4.3 5S / Housekeeping, 4.4 Preventive Maintenance, 06 Work Management, 6.5 Work Execution & Closeout, 10 Continuous Improvement, 10.3 Maintenance Management Improvements, 10.4 Maintenance Practices Improvements, 10.5 Asset Reliability Improvements
Author Title: 
Principal Consultant
Author Employer: 
HP Reliability Inc.
Author Bio: 

James helps organizations understand how world-class maintenance & reliability programs are designed and implemented so that they can be a source of profit. These profits are achieved through improved equipment uptime, improved efficiency in the maintenance department and in the storeroom. This profitability enables manufacturers to stay competitive, contributing to good jobs and prosperous communities. He has worked in various aspects of Reliability and Maintenance for his entire career. In 2015, James founded High Performance Reliability with the purpose of making industry a better place; where individuals and manufacturers possess the resources, knowledge, and courage to sustainably lower their operating costs. James is also the host of the Rooted in Reliability podcast,