Chapter 6: Lean Maintenance and Safety

Lean is making a process run without any activity that is not necessary to support the process. In manufacturing, activities are considered value-added and not value-added. The issue here is, where does safety fit into Lean maintenance? Environmental compliance, or safety of the environment is related to safety. Lean maintenance is completely consistent with high safety, and a responsible attitude toward the environment.

What happens when a company cuts too much money out of maintenance? Immediately, nothing happens. It takes a while to liquidate the good conditions of well-maintained assets. The first signs of the problems coming are subtle. The manufacturing process starts to have increased variation as the assets suffer deterioration. There is also an increase in the workers stress level. The increased stress is the result of having too many jobs for too few workers, and the lack of relief workers. The lack of relief workers means that any small hiccup in attendance crashes the already-stretched schedule. Critical maintenance will not get done. Workers' experience burn-out, and increased tension in the work they do on a daily basis. Cuts that result in these problems are inconsistent with the goals of Lean Maintenance. Under these conditions, safety falls to second or third place.

It is obvious that, when a power cord is frayed, whatever brand of maintenance is followed, it should address the problem immediately. Clear and present danger is not the issue of these discussions. Even potential danger (one step down from clear and present danger), is usually...