Lean Maintenance is sometimes called zero maintenance. It does not mean that there will be no maintenance work done. It simply means that any maintenance work must coincide with the normal operations such that it will not affect the normal flow of company operations. For example, by experience a machine part normally wears out in three months. Two days before the third month is up, the part is replaced and normal operations continue. By doing this machines do not suffer breakdowns or damage caused by failure to replace the part. No additional money is wasted to pay for repairs. Time is not wasted on repairs. Normal production continues. Hence, zero maintenance time is achieved. This is the goal of lean maintenance.
Being proactive is the key in lean maintenance. This system uses maintenance activities that are planned and scheduled. When to conduct maintenance is determined through reliable ways: from the individual judgment of the worker actively using the machine as he practices the 5S process; the weekly Kaizen suggestions for improvement events; computer managed maintenance system and the maintenance technicians working in accordance with their work order. Parts are provided on a just-in-time basis by a lean maintenance storeroom that is an adjunct of an engineering group. This group is essential for it performs analysis of the root causes for failure of parts, analysis of the effectiveness of procedures for maintenance, and predictive maintenance. All these ensure that the date and period for replacement or maintenance is done even before breakdown occurs.
This value stream-oriented maintenance must be implemented as part of the goal of eliminating all kinds of waste in every stage and area of the production of goods. This is now the end goal of Lean Manufacturing. So, for lean manufacturing to be achieved, lean maintenance must first be instituted.
In scope, lean manufacturing is the bigger circle while inside and lending support is lean maintenance; and, within lean maintenance is the core of being Pro-Active.