KAIZEN™ in Maintenance

From Repairing and Managing Breakdown Risks
To Integrating with Production and Preventing Upstream Flow

Get started

of maintenance hours are unplanned

.3m$

is the cost per hour when a plant is down

of companies relate downtime to service level

of companies invest in growing productivity

of cost reduction with preventive maintenance

Mission

If you have the mission of:

• Achieving zero equipment waste, by working on stoppages, materials, energy and spare parts

• Reaching world-class mean time between failures and mean time between accidents values

• Complying with health and safety best practices to guarantee zero accidents

Challenges

Roadblocks impeding you from fully succeeding

Ensuring that the planned maintenance schedule is aligned with the production plan despite constant changes

Small lots and high customization require flexible and versatile equipment

Technical skills and knowledge are lost from the business as people come and go

Keeping up with new technologies to collect and treat data for process control

Satisfying regulatory requirements and ensuring safety standards

Improving equipment efficiency without compromising product quality and customer satisfaction

Solutions

You need to develop:

Kobetsu KAIZEN™

• Develop structured problem-solving capabilities to effectively identify and eliminate root causes

• Standardize the communication and training procedure on new process guidelines

• Implement structured problem-solving capabilities, to effectively identify and eliminate root causes

• Standardize the communication and training procedure on new process guidelines

Autonomous Maintenance

• Transfer knowledge between production and maintenance teams

• Give production teams the autonomy to intervene with minor equipment issues

• Create simple maintenance routines to reduce MTBF

• Transfer knowledge between production and maintenance teams

• Give production teams the autonomy to intervene on the equipment

• Create simple maintenance routines to reduce MTBF

Planned Maintenance

• Develop and deliver planned maintenance plans that improve equipment reliability

• Maintain a spare parts stock level that is cost-efficient and guarantees the desired MTTR

• Research and develop new technology to help monitor the equipment and improve performance

• Develop and deliver planned maintenance plans that improve equipment reliability

• Maintain a spare parts stock level that is cost-efficient and guarantees the desired MTTR

• Research and develop new technology to help monitor equipment and improve its performance

Education & Training

• Develop and implement a long-term training plan for each employee

• Guarantee that lessons learned and technical knowledge gained are passed on between team members

• Develop and implement a long term training plan for each employee

• Guarantee that lessons learned and technical knowledge gained are passed on between team members

Health & Safety

• Create a working environment that minimizes the risk of employee injury

• Comply with standards for waste management and emission reduction

• Create a working environment that minimizes the risk of employee injury

• Comply with standards for waste management and emission reduction

Kobetsu KAIZEN™ autonomous and planned maintenance education & training Health & safety

Reach best-in-class performance

Production Efficiency in Process Industry

Spare Parts Planning

Autonomous and Planned Maintenance

Start with a Value Stream Analysis

During the Value Stream Analysis workshop, we will create an improvement vision for your organization, business unit or department. By working alongside your team, we will understand the current state of the business processes, design the Value Stream Vision and define an implementation plan to achieve the desired results.

See VSA brochure

Ready to Start?

Find key opportunities in your maintenance processes are by conducting a Value Stream Analysis.

* required fields