What Are the Benefits of Lean Maintenance and TPM?
Maintenance is often viewed as a function that does not [...]
Maintenance is often viewed as a function that does not add value to an organization; therefore, resources should not be allocated to it, as this would amount to a waste of those resources.
However, we must keep in mind that maintenance is an essential function in any production process, as it is what allows the process to continue operating under optimal conditions, ensuring that its objectives are met without errors and at the lowest possible cost, This requires that maintenance be carried out as quickly and efficiently as possible, and a good way to achieve this is by using basic Lean tools, such as 5S, Poka Yoke, the Spaghetti Diagram, and the 5 Whys—or, better yet, more complex tools such as A3, SMED, and Visual Management. Thus, we can describe Lean as a method that helps tasks be performed as quickly and efficiently as possible.
But in today’s highly competitive environment, where it is necessary to minimize costs, maintain very strict quality standards, and increase flexibility while shortening delivery times—all of which place greater pressure on available resources—this is precisely where a thorough implementation of this philosophy is required.
TPM (Total Productive Maintenance), which can improve production processes and make them more profitable by enhancing both the people involved and the assets needed to carry them out.
TPM offers a range of benefits, both tangible—such as improvements in production, quality, costs, and employee motivation—and intangible, such as greater employee engagement, improved work environments, fewer problems, and an enhanced organizational image. These benefits are measurable and evaluable.
Given the interest among managers, engineers, and maintenance technicians, I have developed an outline to explain the main concepts of a Lean Maintenance and TPM plan—specifically, the key elements of a Lean Maintenance and TPM plan. The main objective is to understand how these concepts are applied in practice and how to measure and evaluate them, so that they can then be applied to real production processes. If you are interested in learning about the syllabus and practical exercises, you can find more information about the Lean Maintenance and TPM workshop/course that I am offering. More information.
Article written by: Jorge Asiain Sastre
Senior Mechanical Engineer, CEng MIMechE, MBA
AlterEvo Ltd. European University
