We promise that the LEAN team will identify and reduce waste
Intensive workshop based on these books
Lean means producing your product or service with as little waste as possible.
Defect elimination is the key to reliable maintenance.
This course is designed for all types of maintenance environments, including large and small organizations caring for machinery, buildings and fleets.
Suitable people will come from all levels of maintenance personnel, particularly maintenance workers. Supervisors, planners, managers, and maintenance engineers can also take it.
The course works best when people from different levels, jobs or when people from different plants take it together. A diversity of opinions and experiences is desired.
We promise that the LEAN team will identify and reduce waste. Defect elimination will reduce the amount of future maintenance work.
Direct Benefits from this course:
This course teaches specific techniques for locating and attacking waste and reducing costs of operation. The outcome of the session is a series of Lean/DE projects ready for execution. The projects will be designed, prioritized and justified
Lean projects are inexpensive and pay for themselves many times over:
Reduce waste and get other improvements in the maintenance shop:
In a lean shop people are more motivated
Unique application of Hybrid Training
Both Lean and Defect Elimination are Small Improvement Project (SIP) based programs. All advantages come from action. The information you learn will only make a difference if it is applied in your plant.
To support a successful implementation, we have designed virtual follow up meetings to review projects, acknowledge wins and discuss what we learned from the SIPs that did not succeed.
All the Lean and Defect Elimination courses benefit from this scheduled follow-up. We recommend 4- 1 ½ hour virtual sessions. The team is left with an agenda and a structure to manage the program ongoingly.
Examples of complete projects in a school district with top 2 ratings
Gold Effect on A/C electric consumption of increasing the set point of a school from 75.5 to 77 F. The school wide set point in the Jupiter school was raised from 75.5 to 77. No complaints were registered. The electricity usage dropped by 10% resulting in a $7000 year savings per school with an immediate total approaching $315,000 (45 schools on DDC controls) for the district. Additional recommendations for savings from new thermostats in modular units. Gold star because there is little investment, large potential savings, and immediate returns.
Silver Impact of the use of stabilizer on the consumption of chlorine in the pools. The team added $225 of stabilizer to a pool. They charted chlorine usage for 1 week before and 1 week after stabilizer was added. Chlorine usage in the test pool dropped by $80 per week. Potential savings is $4000 per year per pool. Silver star is awarded because investment is small while the payback is large and immediate. This technique can easily be applied to all district pools where stabilizers are not being used.
Compare circulating pumps. Project compares an existing cast Iron circulating pump to a smaller and lighter stainless-steel pump. The smaller pump has been in use in the district for 7 years. Analysis of replacement cost, reliability, energy usage, and complexity of installation shows that the smaller stainless pump is clearly superior. It costs $150 less to purchase, is more reliable, and uses about $7/yr less electricity. Recommendation: replace all circulating pumps with stainless ones as they fail.
Testing premium edger blades verses currently used inexpensive 10″ blades. Premium blades cost $8 each and the current blades cost $2 each. The blades were tested under real conditions during alternate weeks. The conclusion was to stay with the current blades used by the district.
Comparison of individual pothole repair to parking lot resurfacing. Calculations show that resurfacing is economic if there are more then one pothole per 1000 sq’. Pothole repairs are more costly and also only last a short time and are usually done on overtime (to minimize interference to the schools). Resurfacing lasts an average of 6 years and enhances the look of the school.
Comparison of direct drive exhaust fans to belt driven fans. Study shows that belt driven fans are more susceptible to maintenance calls and noisier. Recommendation: In new installations direct drive fans would be less expensive to purchase, quieter to use and require lower maintenance input over the life of the unit. Replacing existing units is not indicated unless extensive other work is needed.
Comparison of the costs of the three dominate door systems used on the beach side of the district. It proved that the best door was the aluminum door with the heavy-duty aluminum jamb. This combination would save over $2000 against wood and over $800 against steel per opening over the 15-year life of the door. They also found that the installation is a major factor in maintenance. Doors that can open all of the way up to 180 degrees or to a wall with a stop have the fewest problems Recommendation: where ever major work on doors is undertaken replace the door with aluminum. Specify aluminum on all new construction.
Virtual Online configuration | Live on-site | Add Hybrid to either online or live |
2-Day 3-Hours 3-Day 3-Hours 4-Day 2-Hours | 9 A.M to 4 P.M with Lunch and breaks | 1 ½ hours per session |
Should be scheduled with sessions about 1-week apart | Contiguous | Should be scheduled with sessions about 1-3 weeks apart |
RED – are interactive exercises of various types
Day 1 Lean maintenance and where it fits in, problem solving
Specific Lean Strategies
Day 2 Finding waste and the development of the Lean Project
Day 1 Lean maintenance and where it fits in, problem solving
Day 2 Looking at every activity of maintenance for Lean ideas
We are flexible about your specific needs for outcomes from the course.
The most basic way is to present a standard course after a brief email conversation about goals and objectives. The courses are tried and tested and have been used to good effect worldwide in many maintenance situations.
The second and most common option involves a one-day site visit before the class. This visit allows me to add examples from your facility, adjust the verbal presentation to suit your needs, meet some key players, and see some of the unique problems you face.
involves a more extensive site visit (to be defined) a few weeks before the class. This extra time allows me to customize and add examples from your facility and adjust the verbal presentation to suit your needs. It is always good to meet some of the key players and see for myself some of the unique problems you face.
The third option is to conduct a maintenance audit survey that looks at all the aspects of maintenance, evaluates areas where improvements are possible, and slanting the training to the competencies needed to implement the upgrades uncovered in the survey.
