Malarvizhi.G, is engineering bachelor in electronics and communication and masters in business administration. She has done projects in electronics and marketing in her under graduate and post graduate programmes. She is interested in marketing research. She can be contacted at – gmalar85@gmail.com
Lean maintenance, without this you may lead to decrease in productivity levels and profit in danger. Reduction in cost of the business can be achieved by implementing the methodology of lean maintenance reliability.
All manufacturing environment requires elimination in the downtime and unscheduled maintenance which will decrease their cost. Increase in downtime leads to failure in the shipment schedule resulting loss in sales. To reduce waste preventive measures are preferred.
Grasping the cost of downtime is very important because reducing this cost will immediately increase the profit. This method helps the organization to shine in this competitive world and increase the market share.
Even after the implementation of preventive maintenance, most of the time only reactive measures are taking place in many enterprises. Only tracking and measuring will not help to avoid this reactive measure, we are supposed to eliminate the root cause at the first place.
The root causes and proactive measures can be derived from the Six Sigma's "DMAIC" Y=f(x) analysis. This lean maintenance based on Six Sigma provides the whole concept of preventive maintenance.
Y=f(x)
Where, Y=the problem (downtime, scrap etc),
f(x) = function of x.
Y happens as a function of x, this relationship helps to find the cause and the remedial measures.
Traditional approaches often lead the professionals down the wrong path as they still haven't found the chronic. If the stressor for downtime is known, it becomes easy to prevent the rework incurring cost.
Professionals in lean maintenance reliability have given a method to maintain the reliability as goal. With experience and control system we can determine the cause of breakdown and protect the equipment from the stresses to which it is subject. Six Sigma's "DMAIC" guidelines are,
D - Define the problem,
M -Measure the problem,
A - Analyze how to eliminate the problem,
I - Implement the solution,
C - Control the solution continuously.
Stress eliminination like power surge, heat, hydraulic contamination, vibration, dirt built-up etc provides availability of machine and increase uptime. Further development in lean maintenance reliability is a going on process for making it possible in 30 - 60 days. Its result includes reduction in mechanical, hydraulic system, electronic system downtime by 50%, 80%, 92% respectively.
Lean manufacturing maintenance will result in 70 - 92% decrease in unscheduled downtime. With skilled and proper expertise than most nearing retirement persons we can implement this method in 30 -60 days.
Society of Manufacturing Engineering (SME) helps to manage it right. SME has a group called Product and Process design and Management Technical Community, where they are gathering the professionals and coming out with better ideas regarding lean maintenance reliability. Participation of manufacturers in this gathering will help them to come out with competitive business.
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