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Application of lean principles in maintenance management: a case study

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Resumo:This work presents the application of Lean principles in maintenance management through a case study supported by a company that provided its data and procedures for analysis. The study was conducted following the DMAIC cycle (Define, Measure, Analyze, Improve, and Control), enabling a detailed evaluation of maintenance processes, identifying failures, developing improvement actions, and controlling maintenance performance indicators. Each DMAIC phase was structured with Lean and Quality tools. In the ‘Define’ phase, the project scope, objectives, and limitations were established using a Project Charter and a SIPOC diagram, which studied 6 processes in the maintenance system. In ‘Measure’, the history of maintenance orders and performance indicators was studied. The ‘Analyze’ phase identified the causes of inefficiencies using the Ishikawa Diagram, and in ‘Improve’, an Impact x Effort matrix was developed to select the causes that should be prioritized, enabling the creation of an action plan, using the 4W1H tool, to address these causes. The ‘Control’ phase introduced the ‘Maintenance Failure Profile’, which enables the monitoring of performance indicators, tracking equipment failure modes, and assessing the maintenance team’s efficiency. This tool provides leadership with a detailed view of the maintenance status, enables historical comparisons, and supports data-driven decisions. The project demonstrates that the analysis performed, along with the proposed improvements, has the potential to significantly enhance the efficiency of this company’s maintenance management, without requiring financial investments or structural changes.
Autores principais:Abreu, Gustavo Ventura Ferreira de
Assunto:Maintenance Lean DMAIC Process improvement
Ano:2025
País:Portugal
Tipo de documento:dissertação de mestrado
Tipo de acesso:acesso aberto
Instituição associada:Instituto Politécnico de Bragança
Idioma:inglês
Origem:Biblioteca Digital do IPB

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