TABLE OF CONTENTS The work order system is one of the most confusing areas for Lean maintenance proponents. On one hand we have the indisputable value of accurate data when investigating other Lean projects. On the other hand is the high cost of collecting the data in the first place. For example, the Municipality of Dubai in the UAE has over 600 buildings (and growing). They have 40 people doing data entry alone. The Lean question is, can this amount of effort be justified? What if we made the 40 people redundant (or reassigned them to other tasks within the municipality, which is more in keeping with Lean rules), and went back to paper work orders and verbal instructions?
One observable phenomenon is that, when work order systems are installed and followed, the discipline seems to improve the productivity of the people in the trades. The instruction that all work must be reported seems to have a positive effect. There are surely psychological reasons for this improvement but it seems that the systems often pay for themselves in higher productivity. Such an advance in itself is not enough to recommend installing a CMMS. We have to look for other advantages.
Out of all the approaches to waste reduction and Lean Maintenance, at the top of every list, is doing the right job right, the first time. Two issues with different causes are described here. There is nothing fatter then having to return to a job...
