How efficient is your preventive maintenance program? The reality is that the typical preventive maintenance program achieves a staggeringly low 25-30% efficiency in labor hours. Where do the other hours go?

Predictive Service utilizes techniques based on Lean principles to identify waste in the PM work process. Over the next few weeks, this blog series will identify each type of waste to target for elimination to achieve efficiency in the PM process.

7 Wastes of Preventive Maintenance: Over-Production (1 of 7)

Producing more than the customer needs

The first part of the seven wastes is over production. Waste results from producing more than is required at any given moment by the next workstation or the final customer. Typical examples are; producing product to stock based on sales forecasts, producing more parts to avoid lost time due to long set-ups, and batch process resulting in extra output in case of breakdowns.

Over-Production Waste in PMs: 

  • Redundant activities resulting from disconnected systems and/or work orders
  • Tasks that cost more than the value provided. An example would be OEM manuals that are well-intentioned, but without justification
  • Over PM on non-critical equipment, specified by PMs copied from like type critical equipment or OEM manuals
  • Performing PM tasks more often than needed
  • Repairing non-urgent items found during a PM when the repair is not immediately required.

The next of the 7 Wastes in our series will be Transportation.

About the Author:

Ed Stanek, Jr. is President of Predictive Service EAM group. Predictive Service’s Enterprise Asset Management (EAM) offerings focus on an optimized life-cycle approach to achieving improved utilization, enhanced performance and reliability while reducing capital and operating costs. Our offerings start at the core, the CMMS and ERP systems and extend to consulting, and reliability services.