Higher Maintenance Blog

Dedicated to elevating the maintenance process

Our blog is designed as a way of sharing some of the tips and techniques that we've learned over the years for implementing our Lean Maintenance Management Systems.  We focus on PM Optimization, Value Stream Mapping, TPM Operator Care and Work Management Optimization tips, but we also post LAI news and events and other information that will be a tremendous help to you in getting the most out of your maintenance program.  Click on the "Read more" link or the title for the full post.

10/18/2013 - 9:22am

 Work that contains errors, rework, mistakes or lacks something necessary

The last of the 7 Wastes is the one that is most frequently targeted, often to the exclusion of the other six. (Over-Production, Transportation, Motion, Waiting,  Processing and Inventory. See our previous posts for more information about the first six wastes.)
10/10/2013 - 9:34am
More materials, parts, or products on hand than the customer needs right now
This 6th waste can be physically and visually identified.  (See our previous blog posts for the first five of the 7 Wastes: Over-Production, Transportation, Motion, Waiting and Processing.)
Inventory in the...
10/02/2013 - 10:04am

Effort that adds no value from the customer’s viewpoint

The 5th of the 7 Wastes, Processing, can be one of the most difficult wastes to identify. (Over-Production, Transportation, Motion and Waiting are the first four and are discussed in our previous posts.)

Waste in processing occurs either when more work is done on a product than is needed to finish it, or when tools and equipment are used in the production process that...

09/19/2013 - 4:09pm
Idle time created when material, information, people, or equipment is not ready
The 4th of the 7 Wastes is Waiting. (See our previous posts for the first three; Over-Production, Transportation and Motion.)
Whenever goods or products are not being moved or processed, the...
09/11/2013 - 10:06am
Movement of people that does not add value

Our last two blog posts discussed the first two of the 7 Wastes; Over-Production and Transportation. The third waste is Motion.
Motion refers to the producer, worker or equipment making the product.  Excessive motion results in waste through unneeded...
09/05/2013 - 10:03am
LAI has started a new discussion group on LinkedIn for topics contributing to an understanding of how Lean techniques can be applied to a maintenance management program to achieve optimal results from resources.
Improvement initiatives like LEAN focus on eliminating waste first and then protecting product flow. Those of us in the Maintenance Reliability field understand that without reliability in our...
09/04/2013 - 9:25am
Movement of product that does not add value
In our last post, we exposed you to the 1st of the 7 Wastes, Over-Production, which can also have a multiplier effect on all of the other wastes. Transportation is the second of the 7 Wastes.
Any time a product is moved, there is...
08/28/2013 - 10:31am
Producing more than the customer needs right now
The first of the 7 Wastes is Over-Production. Waste results from producing more than is required at any given moment by the next workstation or the final customer.   Typical examples are; producing product to stock based on sales forecasts, producing more parts to avoid lost time due to long set-ups, and...
08/22/2013 - 10:00am

How efficient is your preventive maintenance program?  Most managers would say that they are achieving 70% to 80% efficiency in their work processes.  The reality is that the typical preventive maintenance program only achieves a staggeringly low 25-30% efficiency for labor hours.  Where did the other hours go?

LAI has developed methods for applying recognized Lean techniques for identifying waste in each work type in the preventive maintenance process.   By...

04/02/2013 - 2:52pm

Join us at the Reliability 2.0 conference for "Value Stream Mapping for Maintenance," presented by Ed Stanek Jr, LAI'S President. The presentation will be on Thursday, April 11 from 1:45 to 2:30 pm in Sonoma D at the South Point Hotel, Casino & Spa in Las Vegas.

Summary: As maintenance and reliability professionals, how can we find time to improve reliability with growing backlogs and restrictive maintenance budgets? The answers can be found in...

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