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. This blog series will identify each type of waste to target for elimination to achieve efficiency in the PM process.

Movement of people that does not add value.

Our last two blog posts discussed the first two of the 7 wastes: over-production and transportation. The third waste is motion.

Motion refers to the producer, worker or equipment making the product. Excessive motion results in waste through unneeded reaching, sorting through materials, lifting boxes of parts or walking. Consequences of this type of muda include safety issues and potential damage to products and equipment. Spaghetti diagrams can be used to help identify this waste.

Motion Waste in PMs:
  • Performing PM tasks that can be designed out. Poor equipment design, lack of RCFA.
  • Excessive craft movement around machine. Poorly organized PM tasking order within work order.
  • Excessive guard removal or accessibility. Poor equipment design.

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

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