Lean Maintenance, Six Sigma & Value Creation
A case study

Six Sigma, Lean and Theory of Constraints (TOC) are commonly accepted methods used by upper management for making manufacturing improvements.  However, these same tools, when applied to Maintenance and Reliability (M&R), have been proven to fix maintenance problems which have been unsolvable, drive better performance, reduce costs, and eliminate defects, delighting customers and upper management.

The Value Creation, Lean Maintenance & Six Sigma Workshop, presented by Todd Overbeek, Eastman Chemical and Paul Casto, Meridium at The Maintenance & Reliability Conference, February 15, 2010, will begin with a discussion on creating value through maintenance and reliability (M&R); how to build the M&R business case, including an introduction to the fundamentals of finance and financial reporting; and how to ensure that M&R value is reflected on your company's income statement.

Where to find value, how to measure it, the magnitude of the potential value and how to capture this value will be linked to Six Sigma, Lean Tools and TOC. The basic theory and fundamentals of each of the three methods will be reviewed. A detailed discussion on how these methods can be applied to M&R to create and capture value is included. The seminar material will provide proven approaches and techniques to properly apply both Six Sigma and Lean to M&R. The use of these methods will be illustrated through case studies and a review of actual project results.

You can also hear Paul Casto, Meridium speak on February 17th, 12:45 - 1:30 PM on:

Defining Best Practice for Maintenance Overtime

Overtime is an element of maintenance cost that receives a great deal of focus and it is one of the first areas to be cut when maintenance cost must be lowered. Best practice benchmarks for maintenance overtime have been discussed in numerous text and papers. However, these benchmarks are often given using misleading accounting procedures, poorly defined work processes and lack the detailed business analysis needed to understand the benchmark. This paper will explore the reliability conditions required for effective use of maintenance overtime, the productivity considerations with the use of overtime and the detailed business analysis needed in order to understand the proper benchmark for maintenance overtime.

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