Maintenance has become increasingly important in the restructuring of the industrial sector. However, many companies still lack the implementation of a strategic maintenance plan. To eliminate losses, maximize equipment use, and ensure productivity, organizations adopt the Total Productive Maintenance (TPM) philosophy, based on the Lean philosophy. This work aimed to improve maintenance management, and so, it followed the Action – Research methodology through five sequential steps: Diagnosis, Planning, Action, Evaluation and Monitoring, in this sequence. Preventive and autonomous maintenance plans were developed through employee meetings. The Lean 5S tool and Ishikawa’s diagram were implemented in the painting workplace to improve maintenance management. The results showed an average increase in MTBF Mean Time Between Failures) by 116 h, decrease in MTTR (Mean Time To Repair) by 1.5 h, and an average increase in equipment availability by 3%. Employees felt more comfortable using the equipment for daily tasks.

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Maintenance Management and Application of Lean Tools in a Metalworking Industry: A Case Study

  • José S. Pinto,
  • Rafaela Casais,
  • Genevieve Bakam,
  • Teresa Pereira,
  • Gustavo F. Pinto

摘要

Maintenance has become increasingly important in the restructuring of the industrial sector. However, many companies still lack the implementation of a strategic maintenance plan. To eliminate losses, maximize equipment use, and ensure productivity, organizations adopt the Total Productive Maintenance (TPM) philosophy, based on the Lean philosophy. This work aimed to improve maintenance management, and so, it followed the Action – Research methodology through five sequential steps: Diagnosis, Planning, Action, Evaluation and Monitoring, in this sequence. Preventive and autonomous maintenance plans were developed through employee meetings. The Lean 5S tool and Ishikawa’s diagram were implemented in the painting workplace to improve maintenance management. The results showed an average increase in MTBF Mean Time Between Failures) by 116 h, decrease in MTTR (Mean Time To Repair) by 1.5 h, and an average increase in equipment availability by 3%. Employees felt more comfortable using the equipment for daily tasks.