{"id":14198,"date":"2023-09-01T09:35:40","date_gmt":"2023-09-01T15:35:40","guid":{"rendered":"https:\/\/limblecmms.com\/?page_id=14198"},"modified":"2025-03-24T13:57:48","modified_gmt":"2025-03-24T19:57:48","slug":"lean-maintenance","status":"publish","type":"page","link":"https:\/\/limblecmms.com\/learn\/definitions\/lean-maintenance\/","title":{"rendered":"Lean Maintenance"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><p>[vc_row full_width=&#8221;stretch_row&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1686168792651{background: #152232 url(https:\/\/limblecmms.com\/wp-content\/uploads\/blog-header-hex-bg4.webp?id=9266) !important;background-position: 0 0 !important;background-repeat: no-repeat !important;}&#8221;][vc_column css=&#8221;.vc_custom_1683307506642{padding-bottom: 80px !important;}&#8221;]<header class=\"kd-section-title col-lg-8 vc_col-sm-8 text-center  subtitle-below-title    vc_custom_1693581761966\" ><h1 class=\"separator_off\" style=\"color: #ffffff;font-size: 50;\">Lean Maintenance<\/h1><h2 class=\"subtitle\" style=\"color: #ffffff;font-size:15px;\">Everything you ever needed to know about lean maintenance.<\/h2><\/header><a  href=\"https:\/\/limblecmms.com\/resources\/cmms-buyers-guide\/\"  target=\"_self\"  title=\"\"  class=\"tt_button tt_primary_button btn_primary_color  button-center button-action-link   vc_custom_1742846267151\" ><span class=\"prim_text\">Free CMMS Buyer's Guide<\/span><\/a>\n      <div class=\"entry-meta\">\n         <span class=\"published\">\n            <span class=\"far fa-clock\" aria-hidden=\"true\"><\/span>Last updated on March 24, 2025<\/span>\n            <span class=\"author\"><span class=\"far sway-author-meta\" aria-hidden=\"true\"><\/span>\n            <span>bBrinton<\/span>\n         <\/span>\n      <\/div>\n\n   [\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687442797424{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<span style=\"font-weight: 400;\">Lean maintenance is a strategy that aims to reduce waste and inefficiency in the management of physical assets. It relies on the application of <\/span><a href=\"https:\/\/kanbanize.com\/lean-management\/what-is-lean-management\"><span style=\"font-weight: 400;\">lean methodology<\/span><\/a><span style=\"font-weight: 400;\"> in the realm of asset maintenance and repairs.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Though many manufacturers focus more on the optimization of production using lean principles, it is arguably even more important in maintenance. This area is often a huge drain on any manufacturing concern, <\/span><a href=\"https:\/\/www.researchgate.net\/publication\/251887374_A_Comprehensive_Approach_for_Maintenance_Performance_Measurement\"><span style=\"font-weight: 400;\">accounting for up to 40% of total production costs.<\/span><\/a><\/p>\n<p><span style=\"font-weight: 400;\">Waste in maintenance is a perennial problem due to a plethora of inefficient practices, such as:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Excessive maintenance\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Unnecessary transportation of spares<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Walking back to a central location after every task to pick up new work orders<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Wasting time searching for tools and replacement parts\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Work order pile-ups due to poor inventory management<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Premature replacement of costly spares<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Delays and downtime due to slow processing or overprocessing<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Extra expenses to correct servicing errors and repair defects<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Lean principles can make a difference here through tactics like smart proactive maintenance, digital work orders, improved leadership and worker training, Kaizen events, and distributed MRO inventories. We discuss all of those and more in the following sections. <\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687442797424{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2><span style=\"font-weight: 400;\">Table of Contents<\/span><\/h2>\n<p><a href=\"#process\"><span style=\"font-weight: 400;\">Why should you apply lean principles to maintenance?<\/span><\/a><br \/>\n<a href=\"#types\">Prerequisites for running lean maintenance operations<\/a><br \/>\n<a href=\"#examples\">Advanced concepts and tools for developing a lean maintenance workflow<\/a><br \/>\n<a href=\"#setup\">How to set up a basic lean maintenance workflow<\/a><br \/>\n<a href=\"#last\">Create a lean maintenance department<\/a>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687440273251{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"process\">Why should you apply lean principles to maintenance?<\/h2>\n<p><span style=\"font-weight: 400;\">Using a lean approach in maintenance has the potential to bring massive improvement to vital aspects of manufacturing. Without proper maintenance, machines will break down and halt the production process \u2013 messing with your maintenance schedules and shortening the life span of your equipment.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Lean maintenance helps you do more (effective) maintenance work with fewer resources. Maintenance departments that are experiencing staffing issues can still deliver better equipment availability and reliability.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Through the implementation of lean maintenance, you are forced to <\/span><b>identify and eliminate actions that waste your internal resources, improve inefficient processes, and speed up your <\/b><a href=\"https:\/\/limblecmms.com\/blog\/emergency-maintenance\/\"><b>emergency maintenance response<\/b><\/a><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The end result?<\/span><\/p>\n<p><span style=\"font-weight: 400;\">A streamlined maintenance process, and a significant reduction in <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-cost-explained\/\"><span style=\"font-weight: 400;\">the overall cost of maintenance<\/span><\/a><span style=\"font-weight: 400;\">, while delivering an equal or better service. <\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row content_placement=&#8221;middle&#8221; kd_background_image_position=&#8221;vc_row-bg-position-bottom&#8221; kd_top_separator_style=&#8221;skew-left&#8221; kd_top_separator_height=&#8221;separator-height-small&#8221; kd_bottom_separator_style=&#8221;skew-left&#8221; kd_bottom_separator_height=&#8221;separator-height-small&#8221; kd_top_separator=&#8221;true&#8221; kd_bottom_separator=&#8221;true&#8221; css=&#8221;.vc_custom_1682969636891{margin-bottom: 40px !important;padding-top: 120px !important;padding-right: 40px !important;padding-bottom: 50px !important;padding-left: 40px !important;background: #dde4e8 url(https:\/\/limblecmms.com\/wp-content\/uploads\/cta-laired-hex-4.webp?id=9077) !important;background-position: center !important;background-repeat: no-repeat !important;background-size: cover !important;border-radius: 0px !important;}&#8221; css_tablet_landscape=&#8221;.vc_custom_1682969636891{padding-bottom: 80px !important;}&#8221; css_tablet_portrait=&#8221;.vc_custom_1682969636891{padding-bottom: 80px !important;}&#8221; css_mobile=&#8221;.vc_custom_1682969636892{padding-bottom: 80px !important;}&#8221;][vc_column][vc_row_inner kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner]<header class=\"kd-section-title col-lg-12 text-center  subtitle-below-title kd-animated fadeIn   vc_custom_1687971311556\" data-animation-delay=200><h2 class=\"separator_off\" style=\"font-size: 42px;font-weight: 500;margin-bottom:30px;\">The Essential Guide to CMMS<\/h2><h6 class=\"subtitle\" style=\"color: #152232;\">Download this helpful guide to everything a CMMS has to offer.<\/h6><\/header>[\/vc_column_inner][\/vc_row_inner][vc_row_inner content_placement=&#8221;top&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner width=&#8221;1\/2&#8243; css=&#8221;.vc_custom_1631866454223{padding-right: 50px !important;padding-left: 0px !important;}&#8221; offset=&#8221;vc_col-lg-6 vc_col-md-12 vc_col-xs-12&#8243; css_tablet_landscape=&#8221;.vc_custom_1631866454223{padding-right: 0px !important;}&#8221; css_tablet_portrait=&#8221;.vc_custom_1631866454223{padding-right: 0px !important;}&#8221; css_mobile=&#8221;.vc_custom_1631866454224{padding-right: 15px !important;}&#8221;][vc_raw_html]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[\/vc_raw_html][\/vc_column_inner][vc_column_inner width=&#8221;1\/2&#8243;][vc_single_image source=&#8221;external_link&#8221; alignment=&#8221;center&#8221; css_animation=&#8221;fadeIn&#8221; custom_src=&#8221;https:\/\/3975608.fs1.hubspotusercontent-na1.net\/hubfs\/3975608\/Content%20Downloads\/CMMS%20Guide%20mockup.png&#8221;][\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687440273251{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"types\">Prerequisites for running lean maintenance operations<\/h2>\n<p><span style=\"font-weight: 400;\">Shifting to lean maintenance results in a major or minor overhaul of nearly all aspects of maintenance. To get started, you will require a mix of several systems, processes, and philosophies, which form the core of lean maintenance you can build upon.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\"><img loading=\"lazy\" decoding=\"async\" class=\" wp-image-4522 aligncenter\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-300x157.jpg\" alt=\"prerequisites for establishing lean maintenance operations\" width=\"499\" height=\"261\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-300x157.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-1024x534.jpg 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-768x401.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-451x235.jpg 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-554x289.jpg 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-93x49.jpg 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-540x282.jpg 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance-100x52.jpg 100w, https:\/\/limblecmms.com\/wp-content\/uploads\/Lean-Maintenance.jpg 1200w\" sizes=\"auto, (max-width: 499px) 100vw, 499px\" \/>1. A proactive maintenance strategy<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Many manufacturers rely on a passive, reactive maintenance strategy to cut down on initial costs. But this outdated approach can prove to be more costly in the long run. Waiting for critical assets to fail before repair\/replacement is inefficient \u2013 which is exactly what lean maintenance is trying to eliminate.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In contrast, a proactive approach aims to negate the problem before it gets a chance to fully manifest. With strategies like preventive and predictive maintenance, you can reduce the risk of sudden equipment failures and production delays. The focus is on establishing optimal servicing and replacement schedules for degrading parts.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">2. CMMS software to streamline maintenance work<\/span><\/h3>\n<p><a href=\"https:\/\/limblecmms.com\/cmms\/\"><span style=\"font-weight: 400;\">A computerized maintenance management system (CMMS)<\/span><\/a><span style=\"font-weight: 400;\"> is the bare minimum to improve efficiency in everything from work order management, overall planning, maintenance scheduling, spare management, budgeting, worker management, and more.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Large industrial organizations looking to implement lean maintenance will often want to integrate CMMS with their existing ERP system. This forms a strong foundation for <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/eam\/\"><span style=\"font-weight: 400;\">effective Enterprise Asset Management (EAM)<\/span><\/a><span style=\"font-weight: 400;\">.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">As it requires enhanced digital capabilities across the entire company, the EAM approach is viable for firms that have already adopted digital transformation. For an initial foray into lean maintenance, a <\/span><a href=\"https:\/\/limblecmms.com\/cmms\/cmms-software\/\"><span style=\"font-weight: 400;\">cloud-based CMMS system<\/span><\/a><span style=\"font-weight: 400;\"> can be considered an adequate starting point.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">3. Up-to-date list of asset inventory\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Having a <\/span><a href=\"https:\/\/limblecmms.com\/blog\/asset-inventory-management\/\"><span style=\"font-weight: 400;\">fully updated inventory of all your core assets<\/span><\/a><span style=\"font-weight: 400;\"> is mandatory for lean maintenance. You can use this to plan your repair schedules, spare part requisition processes, and allocation of maintenance teams.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">A well-maintained asset inventory ensures that every machine or system is accounted for \u2013 failure in even a minor sub-system can bring down the entire production line. To prevent this, manufacturers need efficient and proactive maintenance of <\/span><i><span style=\"font-weight: 400;\">all assets.\u00a0<\/span><\/i><\/p>\n<h3><span style=\"font-weight: 400;\">4. Operator training and autonomy<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Excessive oversight by maintenance managers often leads to slowdowns and inefficiencies within the maintenance system. Firms and managers need to embrace the concept of increased autonomy on the work floor in lean maintenance.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">And this requires a team of highly trained, preferably multi-skilled repair technicians. Apart from basic training in the use of assets and heavy machinery, you will also need to train your teams to act decisively when problems arise.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Operators need a clear understanding of their duties and responsibilities within the maintenance process. This helps create a smooth flow in autonomous maintenance, where everyone is aware of what is required from them.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">5. Leadership change and lean culture<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Lean maintenance often requires a significant change in how systems are managed \u2013 instead of overt centralization of power, it focuses on increased autonomy at the lower levels. This cannot happen without a profound change in attitudes about the role of leadership.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In particular, you will have to address the changing roles\/responsibilities of managers and supervisors. Instead of controlling teams, they will need to perform a more positive role in supporting those autonomous teams on the ground.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The system relies on a flatter organizational structure with fewer levels of management. The focus is more on the shop floor \u2013 not at the top and middle layers of management. This requires adequate preparation and planning but will inevitably lead to continuous improvement. <\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687440273251{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"examples\">Advanced concepts and tools for developing a lean maintenance workflow<\/h2>\n<p><span style=\"font-weight: 400;\">The lean approach in manufacturing has evolved over the decades into a rich and complex system of different advanced concepts, philosophies, and tools. In this section, we provide a brief introduction to important concepts that can be used to <\/span><a href=\"https:\/\/limblecmms.com\/blog\/work-order-management\/\"><span style=\"font-weight: 400;\">optimize maintenance work<\/span><\/a><span style=\"font-weight: 400;\">.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Total productive maintenance (TPM)<\/span><\/h3>\n<p><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/total-productive-maintenance\/\"><span style=\"font-weight: 400;\">TPM is the bedrock<\/span><\/a><span style=\"font-weight: 400;\"> on which the entire tower of lean maintenance stands. It is a holistic approach with one core aim \u2013 try to achieve perfect production with minimal breakdowns, delays, or accidents to your assets and equipment.<\/span><\/p>\n<p><span style=\"font-weight: 400;\"><img loading=\"lazy\" decoding=\"async\" class=\" wp-image-733 aligncenter\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-300x300.jpg\" alt=\"The structure of total productive maintenance - TPM pillars\" width=\"500\" height=\"500\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-300x300.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-150x150.jpg 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-768x768.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-238x238.jpg 238w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-292x292.jpg 292w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-60x60.jpg 60w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-405x405.jpg 405w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars-100x100.jpg 100w, https:\/\/limblecmms.com\/wp-content\/uploads\/2018\/07\/The-structure-of-total-productive-maintenance-TPM-pillars.jpg 800w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/>It emphasizes <\/span><a href=\"https:\/\/limblecmms.com\/blog\/autonomous-maintenance\/\"><span style=\"font-weight: 400;\">proactive maintenance by autonomous teams<\/span><\/a><span style=\"font-weight: 400;\">, who are fully trained and supported to the hilt by supervisors and top-level executives.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">5S philosophy<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">There <\/span><a href=\"https:\/\/asq.org\/quality-resources\/lean\/five-s-tutorial#:~:text=5S%20is%20defined%20as%20a,reduce%20waste%20and%20optimize%20productivity.&amp;text=The%205S%20philosophy%20applies%20in,visual%20control%20and%20lean%20production.\"><span style=\"font-weight: 400;\">are five keywords<\/span><\/a><span style=\"font-weight: 400;\"> in this process that all start with the letter \u201cS\u201d in Japanese \u2013 <\/span><i><span style=\"font-weight: 400;\">Seiri, Seiton, Seiso, Seiketsu, and Shitsuke. <\/span><\/i><span style=\"font-weight: 400;\">They involve the removal of unnecessary tools\/materials, neat arrangement of tools, frequent cleanups, emphasis on a clean and perfect work area, and instilling such behavior into habits at the workplace. The aim of the 5s process is the creation of an efficient, clean, and safe workplace with minimal wastage.<\/span><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\"><img loading=\"lazy\" decoding=\"async\" class=\" wp-image-4521 aligncenter\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example-206x300.png\" alt=\"\" width=\"500\" height=\"728\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example-206x300.png 206w, https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example-164x238.png 164w, https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example-201x292.png 201w, https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example-41x60.png 41w, https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example-279x405.png 279w, https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example-69x100.png 69w, https:\/\/limblecmms.com\/wp-content\/uploads\/5S-checklist-example.png 470w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/>5S example: Workplace scan diagnostic checklist<\/span><\/i><\/p>\n<h3><span style=\"font-weight: 400;\">Distributed MRO inventory\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Instead of centralized storerooms for spares, the lean approach emphasizes the creation of multiple store locations closer to the area of use. These stores will contain relevant, area-specific parts and tools. Lean stores require standardized materials and long-term planning\/forecasting based on CMMS tracking data to ensure maximum availability without holding a huge inventory stock.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Just-in-time inventory management\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Lean manufacturing is often called JIT manufacturing. In a maintenance context, JIT involves changes to inventory management. Firms will only place orders for essential spares or tools. It requires a well-planned maintenance schedule with in-depth knowledge about the condition of individual assets.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Successfully implementing JIT practices in MRO inventory management requires capable <\/span><a href=\"https:\/\/limblecmms.com\/cmms\/spare-parts-inventory-software\/\"><span style=\"font-weight: 400;\">spare parts management software<\/span><\/a><span style=\"font-weight: 400;\"> combined with <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/predictive-maintenance\/\"><span style=\"font-weight: 400;\">predictive maintenance<\/span><\/a><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Kaizen events<\/span><\/h3>\n<p><a href=\"https:\/\/mag.toyota.co.uk\/kaizen-toyota-production-system\/\"><span style=\"font-weight: 400;\">Pioneered by Toyota<\/span><\/a><span style=\"font-weight: 400;\">, Kaizen in Japanese means \u201cchange for good\u201d or \u201cimprovement.\u201d In business, Kaizen events mean activities that are regularly conducted with the aim of continuous optimization of processes and systems. It tries to eliminate waste and redundancies by constantly looking for problem areas that can be further improved.<\/span><\/p>\n<p><span style=\"font-weight: 400;\"><img loading=\"lazy\" decoding=\"async\" class=\" wp-image-4520 aligncenter\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-300x300.png\" alt=\"\" width=\"500\" height=\"500\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-300x300.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-150x150.png 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-768x768.png 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-238x238.png 238w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-292x292.png 292w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-60x60.png 60w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-405x405.png 405w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle-100x100.png 100w, https:\/\/limblecmms.com\/wp-content\/uploads\/kaizen-cycle.png 780w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/>What this means in practice is that maintenance teams should regularly audit and update their processes and procedures to ensure continuous improvement.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Empowered, multi-skilled teams<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Maintenance teams in a lean approach are expected to be autonomous, and capable of conducting all activities \u2013 administrative, logistics, regulations, and more \u2013 all within the strictly defined limits of the maintenance process.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Such teams require diversity, with membership drawn from multiple departments and specializations. Furthermore, to reduce waste and improve crisis management, an emphasis is placed on having members who are skilled in multiple areas of specialization. Achieving that requires well-thought-out training programs.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Work standardization\u00a0\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">If you want to eliminate wasteful actions from your production floor, workers need clear and unambiguous procedures that show how to perform specific tasks \u2013 in other words, it\u2019s time to standardize. This is exactly <\/span><a href=\"https:\/\/limblecmms.com\/blog\/standard-operating-procedure-sop\/\"><span style=\"font-weight: 400;\">what standard operating procedures (SOPs) are for<\/span><\/a><span style=\"font-weight: 400;\">. They outline best practices for repetitive tasks of varying complexity.<\/span><\/p>\n<p><span style=\"font-weight: 400;\"><img loading=\"lazy\" decoding=\"async\" class=\" wp-image-4519 aligncenter\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-300x142.jpg\" alt=\"the purpose of creating SOPs\" width=\"500\" height=\"237\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-300x142.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-1024x483.jpg 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-768x362.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-451x213.jpg 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-554x261.jpg 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-93x44.jpg 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-540x255.jpg 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2-100x47.jpg 100w, https:\/\/limblecmms.com\/wp-content\/uploads\/SOP-2.jpg 1200w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/>Ultimately, SOPs help create a more autonomous working environment with less micromanagement and supervision.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">RCM, RCA, and FMEA<\/span><\/h3>\n<p><a href=\"https:\/\/limblecmms.com\/strategies\/reliability-centered-maintenance\/\"><span style=\"font-weight: 400;\">Reliability-centered maintenance<\/span><\/a><span style=\"font-weight: 400;\">, <\/span><a href=\"https:\/\/limblecmms.com\/blog\/root-cause-analysis-rca\/\"><span style=\"font-weight: 400;\">Root cause analysis<\/span><\/a><span style=\"font-weight: 400;\">, and <\/span><a href=\"https:\/\/limblecmms.com\/blog\/fmea-and-fmeca\/\"><span style=\"font-weight: 400;\">Failure modes and effects analysis<\/span><\/a><span style=\"font-weight: 400;\"> are advanced concepts that can be applied in an effort to improve equipment reliability.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Their primary focus is on ensuring that equipment or manufacturing facilities continue to function reliably in their operating context. They are based on the realization that maintenance has to look beyond concepts like age and life expectancy of individual parts \u2013 to prevent asset failure, firms have to actively monitor the condition of individual systems and parts and assess their reliability.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">By applying RCM, RCA, and FMEA, maintenance professionals can get a better understanding of different failure modes and causes, which enables them to select the right maintenance strategy and schedule for each critical asset.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"setup\">How to set up a basic lean maintenance workflow<\/h2>\n<p><span style=\"font-weight: 400;\">It takes time for an organization to fully embrace lean maintenance, even when you have all the above-mentioned ingredients in place. In the crucial early stages, it is better to take a focused and limited workflow approach. In other words, it is best to run a pilot project.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">1. Choose a system to manage\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">The best option is to start small and pick a problem area within your maintenance wing, one with excessive wastage and costly inefficiencies. Trial your lean <\/span><a href=\"https:\/\/limblecmms.com\/blog\/optimize-maintenance-workflow\/\"><span style=\"font-weight: 400;\">maintenance workflow<\/span><\/a><span style=\"font-weight: 400;\"> here first, and use the Kaizen philosophy to improve and gradually expand to other sectors.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">2. Create maintenance teams\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Make a team of operators who work with the assets in the problem area you selected in the previous step. Try to include experienced maintenance technicians along with regular machine operators whenever possible. It can drastically improve their autonomous capabilities.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">3. Assign leadership\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Pick a maintenance manager \u2013 someone capable of planning and scheduling all the maintenance tasks on the shop floor. Along with an in-depth understanding of the assets, he\/she should also have excellent organizational skills and training\/experience in proactive maintenance.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">4. Create maintenance schedules\u00a0<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Once all the pieces are in place, it is time to focus on the necessary maintenance tasks at hand. Scheduling is usually based on the concept of preventive maintenance. Use CMMS data along with inputs from any monitoring sensors you have on the assets to decide on the optimal maintenance schedules.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">5. Test new procedures and workflow<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Using techniques we outlined in the previous section, you should be able to develop new, more <\/span><i><span style=\"font-weight: 400;\">lean <\/span><\/i><span style=\"font-weight: 400;\">maintenance procedures. The team you established in the second step should try to follow the new workflow as closely as possible. The idea is to see if the changes are applicable in practice, and if things can be improved any further \u2013 before you standardize and expand lean principles to other parts of the production flow.\u00a0 <\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row full_width=&#8221;stretch_row_content&#8221; content_placement=&#8221;top&#8221; css_animation=&#8221;fadeInDown&#8221; kd_background_image_position=&#8221;vc_row-bg-position-bottom&#8221; css=&#8221;.vc_custom_1691073586371{margin-top: 50px !important;margin-bottom: 20px !important;padding-top: 50px !important;padding-bottom: 50px !important;background-color: #f1f6f8 !important;background-position: 0 0 !important;background-repeat: no-repeat !important;}&#8221;][vc_column css=&#8221;.vc_custom_1691073594574{padding-right: 70px !important;padding-left: 70px !important;}&#8221;]<div class=\"kd-calltoaction\" >\n                <div class=\"container\">\n                  <div class=\"cta-text-container kd-animated fadeIn\" data-animation-delay=\"200\"><div class=\"cta-text\"><h3 >Want to see Limble in action? Get started for free today!<\/h3><\/div>\n                    <\/div>\n                    <div class=\"cta-btncontainer\"><a href=\"https:\/\/limblecmms.com\/get-started\/\"  title=\"\" class=\"tt_button tt_primary_button btn_primary_color  button-action-link icon_right kd-animated zoomIn\" data-animation-delay=\"200\">Start Free Trial<span class=\"fas fa-chevron-right iconita\" ><\/span><\/a><\/div>\n                <\/div>\n            <\/div>[\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"last\">Create a lean maintenance department<\/h2>\n<p><span style=\"font-weight: 400;\">Lean maintenance can be a handful, with a lot of complex concepts and tools involved. The comprehensive and intense nature of this approach is simultaneously its greatest strength and its biggest weakness.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Effective implementation of lean principles in production and maintenance can involve high upfront costs, which can have a dampening effect on the enthusiasm \u2013 particularly at higher echelons of management. It also demands profound changes across the organization, inviting pockets of resistance to change at all levels.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">But in these uncertain times, manufacturers have to improve their standards of efficiency to stand a chance. Lean maintenance, being a vital prerequisite for lean manufacturing, will play a pivotal role going forward.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row full_width=&#8221;stretch_row&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1541417547006{padding-top: 100px !important;}&#8221;][vc_column css=&#8221;.vc_custom_1515677064675{padding-right: 0px !important;padding-left: 0px !important;}&#8221;][vc_row_inner kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner]<header class=\"kd-section-title vc_col-lg-6 vc_col-sm-8 text-center  subtitle-below-title kd-animated fadeIn   vc_custom_1679419307921\" data-animation-delay=200><h2 class=\"separator_off\" >Related Content<\/h2><h6 class=\"subtitle\" >Explore our blog for insightful articles, personal reflections and ideas that inspire action on the topics you care about.<\/h6><\/header>[\/vc_column_inner][\/vc_row_inner][vc_row_inner kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1541417551563{padding-bottom: 100px !important;}&#8221;][vc_column_inner width=&#8221;1\/3&#8243;]<div class=\"kd-photobox  \" ><a href=\"https:\/\/limblecmms.com\/blog\/industrial-maintenance-tools\/\"  title=\"Read More\"><div class=\"photobox-img\"><img loading=\"lazy\" decoding=\"async\" width=\"700\" height=\"700\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request.jpg\" class=\"attachment-full\" alt=\"Maintenance Work Order Template\" title=\"The-Ins-And-Outs-Of-A-Maintenance-Work-Request\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request.jpg 700w, https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request-300x300.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request-150x150.jpg 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request-320x320.jpg 320w\" sizes=\"auto, (max-width: 700px) 100vw, 700px\" \/><\/div><div class=\"phb-content text-left \">\n                  <h5 >Industrial Maintenance Tools List and Technology Resources<\/h5>\n                  <p ><\/p><\/div><\/a><\/div>[\/vc_column_inner][vc_column_inner width=&#8221;1\/3&#8243;]<div class=\"kd-photobox  \" ><a href=\"https:\/\/limblecmms.com\/blog\/industrial-maintenance-automation\/\"  title=\"Read More\"><div class=\"photobox-img\"><img loading=\"lazy\" decoding=\"async\" width=\"700\" height=\"700\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management.jpg\" class=\"attachment-full\" alt=\"Equipment Depreciation And Its Role In Asset Lifecycle Management\" title=\"Equipment Depreciation And Its Role In Asset Lifecycle Management\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management.jpg 700w, https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management-300x300.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management-150x150.jpg 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management-238x238.jpg 238w, https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management-292x292.jpg 292w, https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management-60x60.jpg 60w, https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management-405x405.jpg 405w, https:\/\/limblecmms.com\/wp-content\/uploads\/Equipment-Depreciation-And-Its-Role-In-Asset-Lifecycle-Management-100x100.jpg 100w\" sizes=\"auto, (max-width: 700px) 100vw, 700px\" \/><\/div><div class=\"phb-content text-left \">\n                  <h5 >The Present and Future of Automation in Maintenance<\/h5>\n                  <p ><\/p><\/div><\/a><\/div>[\/vc_column_inner][vc_column_inner width=&#8221;1\/3&#8243;]<div class=\"kd-photobox  \" ><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-strategy\/\"  title=\"Read More\"><div class=\"photobox-img\"><img loading=\"lazy\" decoding=\"async\" width=\"700\" height=\"700\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/cmms-vs-cafm-featured.jpg\" class=\"attachment-full\" alt=\"\" title=\"cmms vs cafm featured\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/cmms-vs-cafm-featured.jpg 700w, https:\/\/limblecmms.com\/wp-content\/uploads\/cmms-vs-cafm-featured-300x300.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/cmms-vs-cafm-featured-150x150.jpg 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/cmms-vs-cafm-featured-320x320.jpg 320w\" sizes=\"auto, (max-width: 700px) 100vw, 700px\" \/><\/div><div class=\"phb-content text-left \">\n                  <h5 >Choosing a Maintenance Strategy that\u2019s Right for You<\/h5>\n                  <p ><\/p><\/div><\/a><\/div>[\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_raw_html]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[\/vc_raw_html][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>[vc_row full_width=&#8221;stretch_row&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1686168792651{background: #152232 url(https:\/\/limblecmms.com\/wp-content\/uploads\/blog-header-hex-bg4.webp?id=9266) !important;background-position: 0 0 !important;background-repeat: [&hellip;]<\/p>\n","protected":false},"author":77,"featured_media":0,"parent":10098,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"footnotes":""},"categories":[471],"tags":[],"class_list":["post-14198","page","type-page","status-publish","hentry","category-maintenance-definitions"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.7.1 (Yoast SEO v25.7) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>What is Lean Maintenance? | Limble CMMS<\/title>\n<meta name=\"description\" content=\"Everything you ever needed to know about lean maintenance and how it can help improve 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