Assessing Maintenance Readiness

Click on the button below to complete our on line Maintenance Management Diagnostic and we will send you a short report on how to remove barriers to improvement and place Maintenance at the heart of Operational Excellence.

The diagnostic covers the following maintenance systems.

Lean Asset Management

1. Process control
   How effectively do you identify and resolve operational challenges to ensure each asset is delivering its full potential?

2. Policy Deployment
   How proactive and effective is your approach in addressing the root causes of failures and reducing problem hot spots?

Lean Execution

3. Work Control
   How well-defined are the roles and responsibilities for initiating corrective actions and preventing future incidents?

4. Skill Development
   How structured and comprehensive is your program for developing technical skills and enhancing teamwork within the operations team?

Lean Improvement

5. Planning
   How effective is the standardisation of your key maintenance processes, including asset inspections, servicing, technical data management, work planning, daily operations, cost control, and the management of spares and lubrication?

6. Performance Analysis
   How clearly defined is your long-term vision, and how well do your 12-month and 90-day action plans align to support that vision?

Mobilising Lean Maintenance

The output from the diagnostic provides maintenance management with an agenda for a plan the plan session to map out targeted action plans to deal with priority gaps in Leadership, Execution, and Improvement processes. The deliverables from this first phase is a programme to establish basic asset conditions, upgrade documentation, knowledge, workflow and spares management to establish:

• Lean Asset Management covering preventive maintenance, inspection and servicing routines,

• Lean Execution covering standardisation, systemised workflows and engagement,

• Lean Improvement covering skill development, performance management, focussed improvement and engagement.

Find out how our training, facilitation and coaching support can help you organisation to deliver those gains as part of your current or future improvement programme.

Implementing Lean Maintenance

Lean Maintenance applies Systems Thinking to maintenance practices, shifting the focus from isolated tasks to a comprehensive, end-to-end approach.

Instead of managing tasks independently, systems thinking ensures that maintenance activities are interconnected, defining clear triggers for action and structured responses. The outcome is to move beyond simply preventing downtime to proactively optimising process effectiveness and eliminating waste.

This shift has significant benefits including:

• Extended Component Life – Studies show that a systems-based approach can stabilise and extend component lifespan by up to 50%.

• Improved Efficiency – By optimising maintenance as part of the larger system, material yield, capacity, and energy efficiency see measurable improvements.

• Enhanced Maintenance Value – Rather than reacting to breakdowns, maintenance becomes a proactive force that enhances overall equipment performance.

Lean Maintenance also complements the TPM centre of excellence program by redirecting the time saved from reducing breakdowns towards activities to optimise asset performance. In addition to improving capacity and resilience, this also

• Reduces unplanned interventions such as minor stops to improve operator productivity,

• Stabilises and extends component life,

• Improves process precision, quality yield, energy efficiency,

• Reduces manufacturing costs.

Apply Lean Maintenance principles by building on existing good practices. A good place to start is with an assessment of Maintenance Readiness.