NATIONAL INSTITUTE OF TRANSPORT

DEPARTMENT OF TRANSPORT ENGINEERING

AND TECHNOLOGY

Automobile maintenance management,

AEU 07616

1.Briefly explain the following

a) Lean maintenance
b) Just in time maintenance
c)five waste of maintenance

PREPARED BY NIT/BAE/2017/466
ELIA Alex A

A. WHAT IS LEAN MAINTENANCE?

Lean maintenance is a proactive maintenance operation employing planned and scheduled

maintenance activities through total productive maintenance (TPM) practices using maintenance

strategies developed through application of reliability centered maintenance (RCM) decision

logic and practiced by empowered (self-directed) action teams using the 5S process. “Lean”

phenomenon has enabled manufacturing industries to increase their levels of profitability and

productivity. Combined with other initiatives such as Total Productive Maintenance (TPM),

Lean has encouraged these companies to focus on the efficiency of their production processes.

Those 5S process are five activities for improving the work place environment: sort (remove

unnecessary items), straighten (organize), scrub (clean everything), standardize (standard routine

to sort, straighten, and scrub), and spread (expand the process to other areas).

Lean Maintenance improvement approach that Activity recommends and uses applies the Lean

principles in an appropriate framework specifically adapted for their application to maintenance.

This ensures that the principles applied in the most time and cost-effective manner that is

appropriate, and leads to rapid, measurable improvements in bottom-line performance. The

framework can be adapted further to fit the specific requirements of individual organizations and

their specific issues.

why implement lean maintenance

Many organizations have fallen into the trap of concentrating on the tools and techniques

associated with Lean instead of the reason for their use. In simplistic terms Lean Maintenance

is:

•Doing the right maintenance and,

•Doing those activities in the most effective and efficient manner.

Lean Maintenance is a powerful approach to help identify and eliminate waste related issues and

deliver real bottom line improvements if implementing and managed in the right way.

B. WHAT IS THE JUST IN TIME (JIT)

The just-in-time (JIT) maintenance operate in an ideal environment such as with constant

processing times, smooth and stable demand and uninterrupted processing. However, in a real-

life environment, the JIT system is subjected to various uncertain factors including stochastic

processing times, variable demand and process interruption due to planned preventive

maintenance. Most companies create and hold inventory in excess, meaning they create goods in

anticipation of other orders. The Just in Time method involves creating, storing, and keeping

track of only enough orders to supply the actual demand for the company’s products.

The JIT method ultimately helps companies cut down on waste from making too many products

(or supplying too many goods). Therefore, they don’t use up raw materials that may or may not

actually be necessary to fulfill the orders they have. In turn, it cuts down on the costs they have

for inventory, freeing up cash flow.

Advantages of the Just in Time Method

Again, the Just in Time method of accounting for inventory is advantageous to companies

because of the reduction of waste it offers. If, for example, a company produces six orders of one

product – specifically created for Company A – they have successfully met the need they have.

If they went forward and created ten orders of the same product, they would be doing so with the

assumption that one (or more) other companies would be submitting an order for the same

product. If no other company (or companies) submit an order for the manufactured goods, they
would then have four more products sitting in their inventory that are unnecessary. They would

have wasted the raw materials on the additional products, materials that could have been used

toward the creation of other goods.

The Just in Time method is reliant upon several factors, including:

 A company efficiently using raw materials, leaving little to no raw materials left over

after production;

 Suppliers Supplier Power In Porter’s Five Forces, supplier power is the degree of

control a provider of goods or services can exert on its buyers. Supplier power is linked

to the ability of suppliers to increase prices, decrease quality, or limit the number of

products they will sell. getting the raw materials to the company in a timely way; and

 Companies utilizing the raw materials in a timely way so as to fill orders on a timely

basis.

C. FIVE WASTE OF MAINTENANCE

I. Staff skills and attitude

Some ways staff can contribute to poor maintainability include inadequate skills, operating the

machinery outside its parameters, reactive versus proactive attitude, or simply not working alerts

in a timely manner.

Resolution, help operators by ensuring the system is informative and not only signals failure

mode but has have had inbuilt diagnostics for faultfinding, then armed them with the skills to act

on this information. Provide industry-derived automation training to ensure your staff are

competent in the platforms and equipment used across the plant.

II. Standardization of parts and equipment

It may take some time to ensure new equipment or replacement parts, or interchangeable in the

plant. Create a critical spares list and check lead times on these. Long lead times can cause major

disruption to production and can cost the business billions in extended downtime. The decision

to purchase and store a spare part depends on several aspects, including the company’s size, the

nature of the equipment, and the cost of a spare part.

Resolution, Engage engineering and service experts to review and assess your plant and give you

a comprehensive critical spares list. These should also detail what risk incurred if certain spares

are not kept locally or onsite.

III. Cost control

This is particularly true when speaking about costs and budgets. Sometimes, maintenance

departments, even in large companies, do not have an effective control of their maintenance

costs. That is usually the case during busy times when it is easy to approve purchases to keep the

company working. The problem is that when maintenance issues that need immediate attention

arise, without the right information in terms of costs, expenses and budget, we might make the

wrong decision.

IV. Time to repair/delays

Sometimes, maintenance departments are not as efficient as should be, even when have well-

trained people, effective procedures and enough resources to achieve their objectives.

Occasionally, a poor Total Time to Repair might produce the inefficiencies. In the short term,

when a failure happens, it is satisfying to know that a technician takes just a few minutes to fix
the machine. However, taking a closer look, often we find multiple instances that contributed to

additional delays.

When analyze these situations, we can identify the time lost between the times the machine went

down; to the time, the technicians repair it. There are often also other inefficiencies that impact

wrench time such as personnel having to go to the workshop to get some specific tools or spares,

bringing the wrong tool because the problem was not communicated properly, manuals were not

available, and so on.

V. Not dealing with root causes of maintenance problems

maintenance departments are in a reactive mode; thus maintenance are too busy fixing the

problems to keep equipment running to focus on the root cause of the problems. For example,

maintenance departments fix a conveyor belt repetitively without taking the time to analyze what

was causing the belt to break. The repair itself might only take a few minutes, but if consider the

total time with multiple repairs, lost time, waiting periods, defective products, etc., this

seemingly simple repair has cost the company a lot of money.

Resolution, to tackling this issue is performing a thorough fault isolation process and root cause

analysis to identify and fix the real cause, avoiding future problems. Sometimes, in fast-paced

environments, it is necessary to fix the damaged part. However, it is important to have a system

in place to keep track of the problems, investigate what is happening and address the root cause

before it happens again.