September 2022 - 18

feature | reliability strategies
Eliminating waste
is the first step
toward efficient
maintenance
systems that drive
reliability.
Streamline
Your Maintenance
MAINTENANCE COSTS CAN range from 20% to 60% of a company's
total operating expenses. Depending on the type of industry,
a facility could easily spend half its daily budget just on maintenance
tasks and supplies. While this may seem like an overwhelming
amount, the alternative of having inoperable machines is simply out of
the question. The only sustainable way to reduce costs is to manage the
allocation of resources, i.e., streamline your maintenance operations.
ELIMINATE WASTE
Before discussing streamlining maintenance, it helps to understand
what causes waste. Lean manufacturing is famous for the concept
of identifying and eliminating sources of waste. Unsurprisingly, the
same concepts apply to pinpointing inefficiencies in the maintenance
process.
The first two types of waste are overproduction and overprocessing.
From a maintenance point of view, these types of waste come from
unnecessary servicing. Without a clear and sound basis that initiates
16 | EFFICIENTPLANTMAG.COM
Eric Whitley
L2L
a maintenance requirement, teams are prone to either do too little or
too much. Not performing enough maintenance increases the risk of
breakdowns. Overdoing maintenance results in waste.
While performing maintenance work, three other types of waste
tend to appear: travel time, inventory, and motion. The requirement to
transport spares and materials to perform maintenance work results in
productivity losses. It may be tempting for teams to store excess inventory
to reduce travel-time waste, but any interim and unnecessary or
repetitive actions are considered waste from motion.
The last two types of waste are associated with rework and
unnecessary waiting times. Both of these arise from poor maintenance
scheduling and planning.
IDENTIFY THE CORRECT STRATEGY
The next step toward streamlining maintenance is choosing the most
appropriate maintenance strategy. While reactive maintenance is
not entirely avoidable, it's good practice to keep it to a minimum.
SEPTEMBER 2022
http://www.EFFICIENTPLANTMAG.COM

September 2022

Table of Contents for the Digital Edition of September 2022

September 2022 - Cover1
September 2022 - Cover2
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