Overview

The original choice of the machine is important for running a Lean operation. Lean machines do the job day in and day out for as long as they are needed. They don't need much input so far as maintenance resources are concerned. Although they might not be the cheapest machines, they cost no more than they have to, given their function. These machines have no unused systems or capabilities.

Poorly-selected equipment can almost never be made Lean without complete re-engineering and/ or complete renewal. We can run Lean projects around fat machines, but there will be a limit to our effectiveness. Lean machines (and all other assets) can be viewed from several perspectives. One perspective is the choice of specifications that support Lean operation and maintenance. These specifications could include 'better' choices for components such as bearings, controls, mechanical strategies, and software.

There are machines that are more or less Lean from a manufacturing point of view. There are also machines that are Lean from a maintenance point of view. In this context we need to have machines that are Lean from both points of view.

This Lean journey can take several years. George Koenigsaecker, President of Lean Investments, LLC., tells the story of making Lean machines at Hon manufacturing. "One of the things that is unusual about Lean is that every time you reapply the tools and concepts to a given work area, you will identify new levels of waste and make new improvements. You will not be...