Lean maintenance is defined as delivery of maintenance
services to customers with as little waste as possible. This promotes
achievement of a desirable maintenance outcome with fewest inputs possible.
Inputs include: labour, spare parts, tools, energy, capital, and management
effort. The gains are improved plant reliability (availability) and improved
repeatability of process (less variation).
The fundamental principles of lean are more frequently being
applied to pharmaceutical asset maintenance. One of the most important aspects
of lean maintenance is developing an understanding of the maintenance processes
and applying a risk-based approach. This involves evaluating whether each
element of maintenance practice used adds value to the product and benefits the
customer. Lean maitenance drives efficiency and effectiveness and this ensures
improved quality, equipment performance, and profitability.
Waste maintenance practices are associated with the
following activities:
- Unproductive work –
efficiently doing work that does not increase equipment reliability.
- Delays in motion – waiting
for production equipment to be available to carry out preventive
maintenance.
- Unnecessary motion –
unneeded travel, trips to parts stores, and looking for tools required to
do a job.
- Poor management of
inventory – not having an adequate amount of the right parts at the right
time.
- Rework – having to repeat
tasks due to poor workmanship.
- Under-utilization of
resources – maximizing resources available and harnessing the skill sets
of the maintenance teams.
- Ineffective data
management – collecting data that is of no use or failure to collect data
which is important.
- Misapplication of
machinery – incorrect operation or deliberate operational strategies
leading to maintenance work being done when it needn’t be.
It is important to note that lean maintenance is not simply
an approach to do more with less resources. It enables pharmaceutical companies
to focus resources where they are needed to meet production and regulatory
requirements.
More detail in Lean Maintenance - A risk-based approach.pdf