LEAN
MAINTENANCE
JOEL LEVITT
Industrial Press
New York
Library of Congress Cataloging-in-Publication Data
Levitt, Joel, 1952-
Lean maintenance / Joel Levitt. – 1st ed.
p. cm.
Includes bibliographical references.
ISBN 978-0-8311-3352-8 (hard cover)
1. Plant maintenance—Management. I. Title.
TS192.L4687 2008
658.2’02–dc22
2008010930
Industrial Press, Inc.
989 Avenue of the Americas
New York, NY 10018
Sponsoring Editor: John Carleo
Copyeditor: Bob Green
Interior Text and Cover Design: Janet Romano
Copyright © 2008 by Industrial Press Inc., New York.
Printed in the United States of America.
All rights reserved.
This book, or any parts thereof, may not be reproduced,
stored in a retrieval system, or transmitted in any form
without the permission of the publisher.
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TABLE OF CONTENTS |
Dedication
Foreword
Introduction to Lean Maintenance
1.Distinguishing Lean from Everything Else
2.Is There a Right and Wrong Way to Lean?
3.Economics
4.Lean Maintenance and World Class Maintenance
5.Lean Workers
6.Lean Maintenance and Safety
7.Lean Organizations and Maintenance Support
8.Lean Maintenance Parts and Storerooms
9.Lean Maintenance and the Work Order System
10.Lean and the Use of the CMMS to Uncover Waste
11.Enabling Technology for Lean Maintenance
12.Lean Planning and Scheduling
13.Lean Shutdowns, Outages and Turnarounds
14.Lean Fire-Fighting
15.Lean PM
16.TPM and Lean Maintenance
17.Quality
18.Contribution of 5S to Lean Maintenance
19.The Lean Machine
20.RCM and Lean Maintenance
21.Lean and RCA (Root Cause Analysis)
22.Lean Outsourcing
23.Some Lean Tools
24.Where and How to Look for Waste
25.Lean Utilities
26.Translating Lists into Projects
27.Unintended Consequences
28.Lean Projects: Organizational Impact
29.Once a Lean Project has been Chosen for Refinement
30.Micro-Planning
31.Execution
32.Putting the Finishing Touches on the Presentation
33.Publishing Lean Projects
34.How a School District could Save $1,000,000 in O & M Costs and Improve Service!
Bibliography
Glossary
Index
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DEDICATION |
The author has had the profound privilege over the last 22 years to work with maintenance individuals and their organizations that fight to do the right thing for their employees, customers, communities, and the environment. While no one knows what they do but themselves, they do the right thing, even in the middle of the night. Even when others in the company are yelling to cut corners, these men and women take the heat and do the right thing.
It is to these people that this work is dedicated. The prayer might be, may we all measure up to their integrity and aspire to attain their stature. The damnedest thing is that they don’t even know how important they are and no one thanks them. Well, thanks to all of them and thanks to you if you are one of them.
Our guiding light is Benjamin Franklin. He was the first American to make a living from thinking about and publishing Lean ideas.
Joel Levitt2008
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FOREWORD |
I don’t think anyone would deny that humanity has gotten the world into a pickle. As maintenance professionals, the question is, what contributions can we make to do our part to change things for the better? The question of this work is what is the contribution of maintenance to the world? That is a big and sometimes uncomfortable question.
Can better maintenance practices save