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Lean Maintenance July 21, 2022

Using Lean manufacturing at a modular facility

It takes innovation and collaboration to accelerate the design and construction process to bring manufacturing facilities online to produce lifesaving vaccines as quickly as possible.

By IPS
Lean Maintenance June 9, 2022

Introducing Lean manufacturing tools and techniques

Lean manufacturing tools and techniques demands a mental shift among employees, steady elimination of process wastes and perfecting best operational practices.

By Bryan Christiansen
Lean Maintenance February 28, 2022

How Lean methods can improve safety: Creating a safety culture

It is important to create a safety culture that works for the employees and supports client success and satisfaction

By Ian Seuser and Jeremy Oliver
Lean Maintenance February 14, 2022

How Lean methods can improve safety: Focusing on quality and productivity

By focusing on the three-legged stool of quality, productivity and safety, people can safely find a better way of using Lean methods.

By Ian Seuser and Jeremy Oliver
Lean Maintenance December 2, 2021

How to develop and motivate employees towards Lean manufacturing

Lean manufacturing, when done right, can improve productivity and reduce waste on the plant floor. Successful implementation requires buy-in from workers. See three ways to change workers’ perception of Lean and build trust.

By Mary Donelan
Lean Maintenance October 14, 2021

How to avoid COVID-19-related schedule delays using Lean

If implemented effectively, Lean planning practices can help meet critical production start dates and make up for delays caused by the pandemic

By Brandon Darroch and Brian Arend
Lean Maintenance July 8, 2021

Six sigma principles could improve additive manufacturing quality control

Utilizing six sigma principles, team of university researchers and standards groups are working on finding ways to set standards for quality control when it comes to additive manufacturing.

By Miranda Buckheit
Lean Maintenance May 7, 2021

Improved productivity through the kaizen multiplier effect

Team-led improvement ideas boost safety, efficiency and uptime for a precision molding operation.

By Daniel Penn Associates
Lean Maintenance March 31, 2021

What to look for in a manufacturing operating system

Manufacturing operating systems have come a long way and can aid engineers in many ways. The right operating system will be intuitive, efficient and easy to use.

By Cara Winther
Lean Maintenance January 19, 2021

Six steps toward the factory of the future

A solid foundation is required for any initiative

By Mohamed (Mo) Abuali
Lean Maintenance November 18, 2020

Mattress company adopts Lean system

Purple deploys L2L’s Lean execution system to great success

By Eric Whitley
Lean Maintenance December 16, 2019

Applying Lean tactics in the Factory of the Future

The Factory of the Future can maximize the value and performance of every machine and production unit.

By Thomas Brown and Rodney Rusk
Lean Maintenance September 16, 2019

Top 5 Plant Engineering articles September 9-15

Articles about Engineering Leaders Under 40, applying Lean to daily management, improving your skilled workforce, maintaining equipment, and keeping workers safe were Plant Engineering’s five most clicked articles from September 9-15. Miss something? You can catch up here.

By Chris Vavra
Lean Maintenance September 10, 2019

Apply discipline to your Lean daily management

Like soccer, a Lean daily management plan on a manufacturing floor requires team discipline to ensure success.

By Tony Rodriguez and Mike Beauregard
Lean Maintenance February 1, 2019

Blockchain benefits for Lean manufacturing

Blockchain can provide benefits to larger manufacturers looking to improve their Lean operations and reduce waste.

By Becky Morgan
Lean Maintenance January 29, 2019

How Toyota Kata can transform Lean deployment

Toyota Kata seeks to enable organizations to gain and sustain competitive advantage through a cultural aptitude for process improvement and represents an attempt to correct various failure modes that are believed to have hindered past Lean manufacturing initiatives.

By Tyson Ortiz
Lean Maintenance September 13, 2018

2018 Engineering Leader Under 40: Justin Sturek, 37

Manager of Continuous Improvement, The Raymond Corporation, Greene, NY, United States

By McKenzie Burns, Production Coordinator
Lean Maintenance September 3, 2018

AI’s hype hides practical benefits

In the discussion about artificial intelligence (AI) and its uses in everything from video games to shopping trips, the practical applications in the manufacturing realm may get overrun by the hype. As Plant Engineering discussed this month with Kazunobu Morita, chief strategy officer for industry and distribution business unit, Hitachi, Ltd., the use of AI on the plant floor will provide better data to workers and will help bolster the sagging workforce needs in the plant. "It is all about building awareness about the available data and need to unlock the potential of this data to address challenges faced by maintenance teams," Morita told Plant Engineering in the Mid-Year Report that focused on the Plant of the Future.

By Bob Vavra, CFE Media
Lean Maintenance August 7, 2018

Linking manufacturing performance metrics to the life of a business

Creating and measuring performance metrics should be well-defined and reflect the goals of the business that focus on delivering value to clients.

By Brad Staats, Ultra Consultants
Lean Maintenance July 16, 2018

Top 5 Plant Engineering articles, July 9-15

Articles about IoT benefits, the 2018 Lubrication Guide, motor repair, and more were Plant Engineering's five most clicked articles from last week, July 9-15. Were you out? You can catch up here.

By Susie Bak, CFE Media
Lean Maintenance June 25, 2018

Top 5 Plant Engineering articles, June 18-24

Articles about the Lubrication Guide, motor repair, maintenance contracting, and more were Plant Engineering's five most clicked articles from last week, June 18-24. Were you out? You can catch up here.

By Susie Bak, CFE Media
Lean Maintenance June 18, 2018

Top 5 Plant Engineering articles, June 11-17

Articles about motor maintenance trends, condition-based maintenance, best practices for compressor storage, and more were Plant Engineering's five most clicked articles from last week, June 11-17. Were you out? You can catch up here.

By Susie Bak, CFE Media
Lean Maintenance June 11, 2018

Top 5 Plant Engineering articles, June 4-10

Articles about motor maintenance trends, best practices for compressor storage, LEED v4 criteria, and more were Plant Engineering's five most clicked articles from last week, June 4-10. Were you out? You can catch up here.

By Susie Bak, CFE Media
Lean Maintenance May 30, 2018

Improving maintenance reliability and sustainability

Maintenance performance alone will not deliver sustainable performance; it has to come from all aspects of a manufacturing organization.

By James Kovacevic, Eruditio
Lean Maintenance March 23, 2018

When selecting an ERP system, what’s driving your project?

When selecting an ERP system, organizations often start with a drive to become “Lean” and stay competitive.

By Brad Staats, Ultra Consultants
Lean Maintenance October 27, 2017

Four best practices in spare parts management

A comprehensive spare parts management policy should include identifying critical motors, comparing carry costs to downtime, and maintaining spare parts on hand.

By Nicole Dyess, Motors@Work
Lean Maintenance September 21, 2017

Create a winning culture on the plant floor

Maintenance can be improved if companies focus more on improving their operations rather than maintaining what they have.

By Chris Vavra
Lean Maintenance July 13, 2017

Five questions to understand the data that drives business performance

Data crunching enables manufacturers to make better choices when it comes to their operations.

By Michael Mantzke and Robert Jonas
Lean Maintenance July 13, 2017

Creating a culture of service and engagement

Cirtronics has grown into a 175,000 square-foot facility with 200 employees and was recently recognized by the New Hampshire Business of Social Responsibility for its people-centric culture.

By Tim Piotrowski, AME
Lean Maintenance June 28, 2017

The other approach to Lean manufacturing

Using data analysis to find out what the dominant products within a facility are and the processes used to create them and how they flow within a plant facility is a useful way to make a company Leaner.

By Nicole N. Snurkowski, Daniel Penn Associates
Lean Maintenance June 26, 2017

What companies need to know about food processing ERP systems

Companies should look for the food enterprise resource planning (ERP) system that provides the best process visibility.

By George Trudell
Lean Maintenance June 21, 2017

Finding the right engagement strategy

A Lean-minded board of directors can have an influential impact on the direction of an organization and its future.

By Jamie Flinchbaugh and Orry Fiume
Lean Maintenance June 16, 2017

Welcome to the summer of innovation

While we take comfort in familiar ideas, what drives are society is innovation and new ideas that allow us to move forward.

By Bob Vavra, CFE Media
Lean Maintenance June 8, 2017

Three steps for developing a food manufacturing plan

A food manufacturing plan should include situation analysis, goals and objectives, and function and scope to ensure that the plan goes through smoothly.

By Jonah Petoskey, Stellar
Lean Maintenance May 25, 2017

Lean manufacturing becoming Leaner

Lean manufacturing has changed the plant floor in many ways and the future promises everything will become Leaner as companies use real-time data to improve operations.

By Eric Whitley, Leading2Lean
Lean Maintenance May 19, 2017

Find a path to compromise on the plant floor

Nolan Lestage, a utilities supervisor for West Liberty Foods in Mount Pleasant, Iowa, shares his story of his manufacturing experience and the pride he has in his work.

By Leading2Lean
Lean Maintenance May 10, 2017

Three pillars to a reliability program

Moving toward proactive maintenance requires a foundational change.

By Tyler Evans, John Bernet Fluke Corp.
Lean Maintenance April 19, 2017

Complexity requires simplicity for Lean manufacturing

Lean manufacturing and the advent of Big Data have made operations more complex and the company needs to make the operational process as simple as possible to avoid chaos.

By Becky Morgan, AME
Lean Maintenance April 18, 2017

Predictive, preventive, and breakdown maintenance tips

Predictive, preventive, and breakdown maintenance are common maintenance programs that provide their own unique benefits and plant managers should know when to employ them.

By David Manney, L&S Electric
Lean Maintenance April 11, 2017

Manage materials with vending programs

Vending programs can manage materials and provide workers with better access.

By Megan Mullins, John Morton, and Eric King, Motion Industries
Lean Maintenance March 20, 2017

Maintenance meant continuous growth, change

A life in manufacturing means adapting to changes and evolving your mindset to fit the times to grow your skillset as well as the company's.

By Dave Reiber, Reliabilityweb
Lean Maintenance March 16, 2017

Prepare your maintenance program for the IIoT

Companies looking to implement the Industrial Internet of Things (IIoT) into their maintenance program need to understand its benefits and how they can take advantage of its potential by implementing reliability-centered maintenance (RCM) and condition-based maintenance (CBM).

By Steve Mueller, Daniel Penn Associates
Lean Maintenance March 15, 2017

Help wanted: More training, equipment upgrades

Maintenance is crucial, but a lack of resources remains an issue according to respondents for the 2017 Maintenance Survey.

By Bob Vavra, content manager, CFE Media
Lean Maintenance February 15, 2017

Use cable testing to assess a motor’s health

Regular cable testing on motors are designed to help determine if any scheduled maintenance may need to take place and using insulation resistance or polarization index testing can provide some answers.

By David Manney, L&S Electric
Lean Maintenance February 8, 2017

Four preventive maintenance mistakes to avoid

When building a preventive maintenance (PM) program, it's important to ensure the new program represents an improvement over the reactive maintenance it's replacing and that it includes the necessary supportive back-end systems and processes to ensure the program is efficient.

By Smartware Group
Lean Maintenance December 6, 2016

Throughput is mindset based on passion and process

Rapid changes in the market and in technology require managers to continuously troubleshoot, as throughput is a mindset based on passion and process.

By Gary Winslow, Ghafari Associates
Lean Maintenance November 23, 2016

The effect of performance management reviews on Lean manufacturing

Performance management reviews may have mixed results with people, but they can have a very positive effect when trying to apply Lean principles to an organization.

By Cheryl Jekiel
Lean Maintenance November 7, 2016

Using CAPEX as part of a maintenance management strategy

When it comes to managing all aspects of maintenance, capital expenditures (CAPEX) remains one of the key priorities.

By Smartware Group
Lean Maintenance November 3, 2016

Diagnose bearing failures beyond root cause analysis

Take a ‘CSI’ approach to root cause analysis to look beyond the obvious to determine why bearings are failing. Six types of failures and 12 tips for determining the root cause are featured.

By Richard R. Knotek, Motion Industries
Lean Maintenance October 21, 2016

Dos and don’ts for making permanent process improvements

Making process improvements that stick within maintenance organizations is a long-term commitment that requires a cultural change with a specific plan and a strong mandate from management that encourages workers to keep making positive changes on all levels.

By Steve Mueller, Daniel Penn Associates, LLC
Lean Maintenance October 17, 2016

Create a culture of purpose-driven excellence

Building a purpose-driven excellence culture requires leadership to be proactive and engage with their workers and create a culture built on trust.

By Greg Williams, AME
Lean Maintenance October 12, 2016

Six ways to build a manufacturing culture from the bottom up

Companies need to establish an environment and culture where workers are just as active in creating a positive, safe environment as the executives and managers. Consider the six tips below to get started.

By Jill Bellak, AME
Lean Maintenance September 27, 2016

How to overcome potential food plant design construction problems

Companies that are able to communicate clearly and be flexible with their clients during a food plant design construction will have the most success in overcoming potential challenges.

By Justin Landowski, Matt McGrogan, Stellar
Lean Maintenance September 15, 2016

2016 Engineering Leader Under 40: George Parada, 34

Business Unit Maintenance & Reliability Leader, Cargill Salt Inc., Newark, Calif.

By Erin Dunne, CFE Media
Lean Maintenance September 1, 2016

New product development: How to form and manage your creative team

Focus on growth through new product launch readiness and leadership capabilities.

By Lea Tonkin, AME
Lean Maintenance August 29, 2016

Oster-size it: How to Lean into daily improvement

The first step in this "make it yours" approach was to make the company's problems visible.

By Susan Fotovich Mccabe, AME
Lean Maintenance August 24, 2016

Making the grade: How to implement enterprise-wide Lean system

Neptune Technology Group’s two-year Lean transformation

By Susan Fotovich Mccabe, AME
Lean Maintenance September 22, 2015

The quick and dirty about OEE: Key concepts and formulas

Learn these key formulas to calculate overall equipment effectiveness (OEE) and assess Lean performances.

By Steve Mueller, Daniel Penn Associates
Lean Maintenance September 17, 2015

2015 Engineering Leader Under 40: Jesse Dorn, 32

Project/Maintenance Manager, Manufacturing; Victaulic; Easton, Pa.; AAS Tool Making Technology & BS Manufacturing Engineering, Pennsylvania College of Technology

By Amanda Pelliccione, Project Manager and Director of Research
Lean Maintenance September 17, 2015

2015 Engineering Leader Under 40: Nathan Wingate, 26

Utilities and Technology Manager, Cooper River Partners; Goose Creek, S.C.; BS Mechanical Engineering, University of North Carolina—Charlotte

By Amanda Pelliccione, Project Manager and Director of Research
Lean Maintenance September 14, 2015

Sister act

Stacey Bales and Sara Mortensen chart a fresh course for the family business.

By Bob Vavra
Lean Maintenance August 21, 2015

Is Lean relevant in today’s economy?

Despite this hurdle to Lean adoption, the reality is that in today’s highly competitive and unpredictable global economy, Lean is still just as relevant, if not more so, than ever before.

By Shawn Casemore, AME
Lean Maintenance August 21, 2015

5 Ways to Improve Your Plant’s Training Strategy: Your questions answered

Webcast presenter Shon Isenhour answers more viewer questions on new training and devices as well as the best approaches for training and other best practices to consider.

By Shon Isenhour
Lean Maintenance August 13, 2015

Focus on four strategies for a ‘Super Lean’ operation

CMMS can help companies that utilize lean manufacturing in eliminating waste in inventory, waiting, defects, and underused employee creativity.

By Paul Lachance, Smartware Group
Lean Maintenance June 5, 2015

Eco-friendly packaging in the food and beverage industry: Types & benefits

The global green packaging market is expected to grow about 8% over the next five years, with the food and beverage market positioned as the largest consumer of green packaging materials.

By Kyle Lawrence, Stellar
Lean Maintenance May 18, 2015

Optimizing the pick area for shipping operations

Efficiencies gained in shipping can reduce costs, speed products to market, and increase customer satisfaction.

By Howard Klein, MSIE, Daniel Penn Associates
Lean Maintenance April 17, 2015

Gas Technology: Craft brewers watch energy dollars

Smaller microbreweries, especially startups, are often located in facilities that were originally designed for other purposes. These might include warehouses, factories, or store buildings. Space is often at a premium, and compromises in energy systems may be unavoidable.

By Gas Technology
Lean Maintenance April 13, 2015

AME: Death by 1,000 Kaizens

Are your employees ready for the Lean journey or suffering from too many Kaizen events? Before you can ever be successful in integrating Lean practices, it’s important to first understand why employees come to work each day.

By Shawn Casemore, AME
Lean Maintenance April 2, 2015

The mystery of the maintenance backlog explained

There may not be any one correct way to measure backlog, but it is always advised to find that shortlist of backlog calculations that work for you, and measure them consistently. Measuring the size and makeup of your backlog can give you some keen insight into how you are managing your workload in your maintenance organization.

By Mike Gehloff, Allied Reliability Group
Lean Maintenance March 26, 2015

How to eat a chocolate elephant: Step by step method to reduce lead time

To reduce lead time, the first step is to prioritize the operations which will yield the most results, then review transactional history to check actual performance.

By Tom Voss, Daniel Penn Associates, LLC
Lean Maintenance March 6, 2015

Lean’s two key ingredients

Lean programs usually begin with good intentions. But sustaining the effort is the biggest challenge.

By Tony Rodriguez, Daniel Penn Associates
Lean Maintenance January 6, 2015

The benefits of a data-driven maintenance strategy

Seven steps toward utilizing prognostic data analysis to optimize maintenance schedules.

By Moritz von Plate and Julia Heggemann, Cassentec
Lean Maintenance August 22, 2014

Don’t let a few rocks end your Lean journey

Unanticipated circumstances test organization's leadership and resilience during the Lean journey. Here is a list of common challenges faced by organizations.

By Shawn Casemore
Lean Maintenance August 11, 2014

AME announces keynote speakers for Jacksonville conference

Jacksonville conference offers attendees the opportunity to learn from leaders and thinkers in the Lean industry.

By AME
Lean Maintenance August 4, 2014

Reliability lessons from the aircraft industry

Training, discipline, and maintenance keep things flying along

By Al Emeneker, Life Cycle Engineering
Lean Maintenance July 9, 2014

Global Automation and Manufacturing Summit Webinar series starts July 14

Keynote speakers at 2014 Summit will discuss manufacturing excellence, preview presentations in September.

Lean Maintenance July 2, 2014

5 ways to get started with Lean and boost your competitiveness

Lean is about involving people throughout your organization in day-by-day, continuing improvements.

By Paul Kuchuris, Association for Manufacturing Excellence
Lean Maintenance June 11, 2014

Debunking the myths around bearings

From installation to lubrication, 11 ways to protect your assets

By Ian A. Rubin, Emerson Power Transmission Solutions
Lean Maintenance May 6, 2014

Remote monitoring: 5 ways to modernize your operation

The information needed to diagnose, treat—and even predict—plant-floor issues is now little more than an Internet connection away. Industrial organizations are starting to take advantage of better remote access capabilities.

By Jon Furniss, Rockwell Automation
Lean Maintenance March 20, 2014

Webcast: Principles of Lean Maintenance

Lean Maintenance is gaining traction as a sound strategy to keep equipment running and productivity humming. The hardest part is getting started. Plant Engineering presents a Webcast that looks at the steps needed to implement a sound Lean Maintenance strategy on your plant floor and to begin to reap the benefits.

By Plant Engineering
Lean Maintenance March 19, 2014

Leveraging practical 5S tools for Lean and continuous improvement progress

Take advantage of existing resources as your organization ramps up its 5S capabilities – a key to lean and continuous improvement progress.

By Lea Tonkin
Lean Maintenance December 23, 2013

Autonomous maintenance: The peril of eliminating a department

Rick Wheeler, a Principal Consultant with Life Cycle Engineering, explains how autonomous maintenance has a valid role in modern maintenance strategy.

By Rick Wheeler
Lean Maintenance August 23, 2013

AME unveils workshops, tour details for 2013 Atlanta Lean Summit

Educational experiences provide an opportunity to learn from professionals whose expertise demonstrates the various benefits of lean.

By Association for Manufacturing Excellence
Lean Maintenance August 9, 2013

So, how long should bearings last?

While circumstances vary, best practices suggest bearings should last eight to 12 years if properly maintained

By Andy Page, GP Allied
Lean Maintenance August 6, 2013

Best and brightest assemble for 29th AME International “Excellence Inside” Conference

The conference features insightful speakers, excellent networking opportunities, fascinating plant tours and presentations sure to provide a fresh look at lean manufacturing.

By Association for Manufacturing Excellence
Lean Maintenance July 26, 2013

Plant Engineering Energy Study: Less than half of manufacturers conduct energy audits

According to a energy survey by Plant Engineering, only 47% of facilities conduct an annual energy audit

By Plant Engineering
Lean Maintenance June 27, 2013

A well-run storeroom preserves capital, saves time and money

Following best practices and running an efficient, up-to-date maintenance repair and operations (MRO) storeroom can save the company a great deal of money in the long-term with less production downtime and greater use of technical resources

By Wally Wilson, CMRP, Life Cycle Engineering
Lean Maintenance June 25, 2013

Quality is ingrained, rewarded by top manufacturers

ASQ study finds training, financial incentives help boost quality improvements

Lean Maintenance May 23, 2013

GE Aviation expands in Delaware to build engine components

$27 million ‘Lean Lab’ will prove out manufacturing techniques

By Bob Vavra, Content Manager, CFE Media
Lean Maintenance January 21, 2013

Modules for accumulation conveyors

ZoneFlex improves material handling efficiency and features clip-in mounting, switch configuration, and LED diagnostics

Lean Maintenance November 28, 2012

Fine tuning your preventive maintenance schedule

A good CMMS system can deliver the information users need to better fine-tune their PM schedules. If a less-rigorous PM schedule gets the maintenance team slapped with a corrective work order, it’s time to adjust.

By Paul Lachance
Lean Maintenance September 17, 2012

Allied Reliability acquires ABB consulting business

Allied Reliability Group has acquired ABB’s Reliability Consulting business in North America, originally known as HSB RT.

By Allied Reliability Group
Lean Maintenance September 11, 2012

2012 Leader Under 40: Kim Kallstrom, 35

Coordinator II/Program Administrator, The Reliability and Maintainability Center at the University of Tennessee, Knoxville

By Plant Engineering
Lean Maintenance March 27, 2012

Product of the Year winners honored

ePac software was presented with the 2011 Grand Award at the 2012 Engineering Awards in Manufacturing dinner.

By Plant Engineering
Lean Maintenance March 14, 2012

CMMS contributes to total productive maintenance initiatives

When a manufacturing organization embarks on a total productive maintenance (TPM) project, especially maintenance operations, it is critical to get the feedback from any/all people impacted, down to machine operators. So often we hear about utopian desires from upper management related to maintenance operations. TPM would be much more successful if people working “in the trenches” are included in the design, implementation and intended outcomes of the project. This stretches way past the maintenance staff to equipment operators themselves who could be “deputized” to handle elementary quality control and preventive maintenance tasks. CMMS should be the operations management, planning, analysis and audit technology component of any plant TPM strategy.

By Paul Lachance, Smartware Group Inc.
Lean Maintenance February 14, 2012

‘Safety by design’ key topic at global conveyor event

Symposium in Turkey hosted by Martin Engineering focuses on safety, efficiency

By Martin Engineering
Lean Maintenance February 6, 2012

Five tips for better preventative maintenance with CMMS

Turn your strategy from reactive to proactive

Lean Maintenance January 26, 2012

What does your maintenance audit tell you?

Five things to review when studying your maintenance operation

By SMGlobal
Lean Maintenance January 26, 2012

The challenges of maintenance planning

7 tips to get the most out of your process and people

By SMGlobal
Lean Maintenance November 17, 2011

Scheduling preventative maintenance – timing is everything

CMMS Intelligence allows maintenance teams to reduce preventative maintenance and achieve maximum uptime.

By Paul Lachance, Smartware Group Inc.
Lean Maintenance November 1, 2011

POY Finalist: Vertical leveler dock door

Finalist in Material Handling Systems in Plant Engineering’s 2011 Product of the Year competition

By Edited by Gust Gianos, Plant Engineering
Lean Maintenance November 1, 2011

POY Finalist: Curtain wall

Finalist in Environmental Health in Plant Engineering’s 2011 Product of the Year competition

By Edited by Chris Vavra, Plant Engineering
Lean Maintenance November 1, 2011

POY Finalist: Performance index

Finalist in Maintenance Software in Plant Engineering’s 2011 Product of the Year competition

By Edited by Amanda McLeman, Plant Engineering
Lean Maintenance November 1, 2011

POY Finalist: Drum unloaders

Finalist in Manual Material Handling in Plant Engineering’s 2011 Product of the Year competition

By Edited by Gust Gianos, Plant Engineering
Lean Maintenance November 1, 2011

POY Finalist: Battery care kit

Finalist in Manual Material Handling in Plant Engineering’s 2011 Product of the Year competition

By Edited by Gust Gianos, Plant Engineering
Lean Maintenance November 1, 2011

POY Finalist: Forklift monitoring system

Finalist in Material Handling Systems in Plant Engineering’s 2011 Product of the Year competition

By Edited by Gust Gianos, Plant Engineering
Lean Maintenance October 14, 2011

5 total productive maintenance (TPM) myths

TPM has been around industry for over 25 years, and yet is still an new concept to many organizations. There are many myths and misunderstandings about TPM that circulate industry.

By Greg Folts, President, Marshall Institute
Lean Maintenance September 12, 2011

2011 Leader Under 40: Anthony Roach, 31

Engineering and Maintenance Manager, FONA International

By Plant Engineering Staff
Lean Maintenance August 15, 2011

2011 Mid-Year Report: Question 4

Manufacturing leaders discuss the characteristics that successful manufacturing operations have in common.

By Bob Vavra, content manager
Lean Maintenance August 15, 2011

In depth: 35 years in a competitive global market

Wildeck Inc. marked its 35th anniversary with a community open house and celebration. Plant Engineering sat down with Keith G. Pignolet to learn more about the plant’s success.

By Bob Vavra, content manager
Lean Maintenance July 27, 2011

Preventative maintenance – the cost of maintaining equipment

The cost of maintaining equipment can be much higher than we realize. Sustaining equipment for its original design consumes time, labor, materials, tools, facilities, and most importantly lost production.

Lean Maintenance April 25, 2011

AME event: Accounting for Lean enterprise

Seminar: June 21-23, 2011; Pensacola Beach, FL

By Source: Association for Manufacturing Excellence
Lean Maintenance April 21, 2011

AME event: Set-up reduction, total productive maintenance blitz

Seminar: May 17, 2011; San Antonio, TX

By Source: Association for Manufacturing Excellence
Lean Maintenance April 21, 2011

AME event: Sustaining Lean: With a plant tour of NovAtel

Workshop: May 5, 2011; Calgary, Alberta

By Source: Association for Manufacturing Excellence
Lean Maintenance April 19, 2011

AME event: A3 improvement process with tour of Siemens Healthcare Diagnostics

Tour/Workshop: May 3, 2011; Newark, DE

By Source: Association for Manufacturing Excellence
Lean Maintenance April 11, 2011

Tank cleaner

TankJet 360 Fluid Driven Tank Cleaner from Spraying Systems Co. is equipped with a dual- or triple-nozzle hub and high-impact solid stream nozzles that rotate 360° in horizontal and vertical planes.

Lean Maintenance July 6, 2010

Kaman acquisition of Minarik expands motion control, maintenance link

Company seen as "great strategic fit" for Kaman

Lean Maintenance February 28, 2009

The five steps to Lean maintenance

March 5 Webcast features Heinz maintenance manager

By Plant Engineering Staff
Lean Maintenance December 20, 2008

Control loop maintenance necessary

he importance of maintaining PID loops cannot be overstated.

By Plant Engineering Staff
Lean Maintenance December 1, 2008

An easy off solution to repair a greasy mess

Plant Engineering brings you another item from the Tips & Tricks archive

By Plant Engineering Staff
Lean Maintenance August 20, 2008

Sustainability one focus of National Manufacturing Week conference

Green Manufacturing: Business Strategies for Sustainability highlights the conference sessions of National Manufacturing Week and will emphasize concepts such as Lean and green, corporate social responsibility, waste to profit, design for environment, zero waste and environmental sustainability.

By Plant Engineering Staff
Lean Maintenance August 15, 2008

NMW opens with five partner shows

National Manufacturing Week arrives at the Donald E. Stephens Convention Center in Rosemont, IL, Sept. 23-25 as part of the latest Canon Communications blitzkrieg of trade shows.

By Plant Engineering Staff
Lean Maintenance June 15, 2008

‘Lean’ doesn’t always mean less

The phrase “Lean maintenance” lends itself to an onslaught of requisite punch lines … “Our maintenance is so lean … Most professional plant leadership understand that Lean maintenance has nothing to do with thinning out warm bodies, or more directly, reducing maintenance resources.

By John L. Ross Jr., Marshall Institute Inc.
Lean Maintenance May 15, 2008

Don’t get grounded by ignoring maintenance

Perhaps no single quote that came out of the Plant Engineering Manufacturing Summit last month in Chicago better summarizes the state of manufacturing right now than this one: “We are so busy trying to meet tomorrow's build requirements that we don't have time to improve.”

By Bob Vavra, Editor
Lean Maintenance May 15, 2008

Asset reliability drives Lean maintenance

Lean maintenance is the application of Lean philosophies, methods, tools and techniques to maintenance functions.

By Kris Bagadia, PEAK Industrial Solutions LLC
Lean Maintenance April 9, 2008

Global indicators for maintenance and availability performance

When a company wants to compare maintenance and availability performance internally or externally, it needs a common platform of predefined indicators so that it can compare apples to apples.

By Plant Engineering Staff
Lean Maintenance March 17, 2008

A Lean journey

The Society of Manufacturing Engineers has released a new book, "Story of a Lean Journey."

By Plant Engineering Staff
Lean Maintenance January 17, 2008

Stainless steel take-up frames

MRC stainless steel take-up frames for use in food-industry conveyor systems are designed to provide support for conveyor shafts and deliver correct conveyor belt tension while withstanding frequent washdowns and typically harsh chemicals.

By Plant Engineering Staff
Lean Maintenance January 16, 2008

Cleaner, degreaser

Sprayon engine degreaser can remove dirt, grease and varnish from mechanical engines, machinery and tools.

By Plant Engineering Staff
Lean Maintenance January 15, 2008

ASQ event links sustainable growth and Lean

Lean Six Sigma experts from around the world will gather at the 8th Annual American Society for Quality (ASQ) Lean Six Sigma Conference February 11-12, 2008, at the Pointe Hilton Tapatio Cliffs Resort in Phoenix. On tap at the 2008 conference are four of the most noted experts in the implementation of Six Sigma in government, healthcare, manufacturing and the utilities industry.

By Plant Engineering Staff
Lean Maintenance January 15, 2008

Are maintenance workers really different than other shiftworkers?

Many maintenance managers will tell you their workforce is different than other shiftworkers – that their attitudes and behaviors are not the same. Recognizing, understanding and accounting for how maintenance personnel evaluate shift schedules are essential to finding a schedule that will satisfy their needs and give you the required coverage to meet your business needs.

By Bruce Oliver and Dan Capshaw, Shiftwork Solutions LLC
Lean Maintenance November 15, 2007

Online maintenance testing

More than 50 tests are available online for assessing maintenance and production workers. Designed to complement training program development, the online assessments provide administration, scoring and reporting that helps users determine areas of deficiency for their employees. Reports can be exported to Microsoft Excel for review.

By Plant Engineering Staff
Lean Maintenance November 15, 2007

General purpose cleaner

HydroForce Zero VOC general-purpose cleaner is an industrial-strength, aqueous non-aerosol cleaner. It's designed for use on tools, parts, grills, tires, engines and shop equipment. The fluid is non-corrosive with a pH level of less than 11. Biodegradable, nonflammable and non-ozone depleting, the cleaner is available in 32-ounce spray bottles, 1-gallon bottles, 5-gallon pails and 55-gallon drums.

By Plant Engineering Staff
Lean Maintenance October 10, 2007

Cleaner/degreaser

Oil Eater cleaner-degreaser cuts through oil, grease, grime and dirt, encapsulating them into a solution that rinses off easily and leaves no residue.

By Staff
Lean Maintenance August 20, 2007

How effective is your maintenance strategy?

New white paper from Lawson explores the concept of Dynamic Reliability-Centered Maintenance

By Plant Engineering Staff
Lean Maintenance August 15, 2007

Experts lay out a case for ROI of maintenance

Maintenance has always been a cost center in manufacturing, but experts at the July 19 Webcast presented by PLANT ENGINEERING and sponsored by UNICCO Service Company made a compelling case that a proper maintenance program can drive profits and a return on investment. “All manufacturers have to get to operational excellence,” said Tim Goshert, worldwide reliability and maintenance m...

By Bob Vavra
Lean Maintenance July 17, 2007

AME offers seminars for Lean certification

Two upcoming seminars are designed to prepare participants for and give the exam for Bronze Certification in Lean.

By Staff
Lean Maintenance June 15, 2007

AFE offers online classes for maintenance, supervision

The Association for Facilities Engineering offers review classes for Certified Plant Maintenance Manager and Certified Plant Supervisor online to allow plant personnel to take the classes at their desktop, avoiding travel and time away from work. The four-hour CPMM training sessions begin at 12:30 EDT on June 19, and last eight sessions through June and July.

By Staff
Lean Maintenance February 1, 2007

Survey on maintenance and service contracts

Plant Engineering magazine and The Aberdeen Group are seeking feedback from plant management personnel to determine what strategies and approaches top service organizations use to grow service revenues and boost profits with their service and maintenance contract offerings. All respondents will receive a free copy of the benchmark study, “Service and Maintenance Contract Management: Ensur...

By Staff
Lean Maintenance January 19, 2007

SKF acquires Preventive Maintenance Company, Inc.

In a move that strengthens its market leadership in reliability services, condition monitoring products, maintenance strategies and consulting services, SKF USA, Inc. has acquired Preventive Maintenance Company, Inc., Elk Grove Village, IL. Preventive Maintenance Company, Inc. is a market leader in predictive maintenance services for industrial customers in the pulp & paper, metals, food, automotive and other industries.

By Plant Engineering Staff
Lean Maintenance January 19, 2007

Survey on service and maintenance contracts

Plant Engineering magazine and The Aberdeen Group are seeking feedback from plant management personnel to determine what strategies and approaches top service organizations use to grow service revenues and boost profits with their service and maintenance contract offerings. All respondents will receive a free copy of the benchmark study, Service and Maintenance Contract Management: Ensuring Service Chain Profitability , due out in February 2007. All individual responses will be kept strictly confidential.

By Plant Engineering Staff
Lean Maintenance October 24, 2006

International Maintenance Conference goes to Daytona in December

IMC-2006, the 21st International Maintenance Conference, is an event where maintenance and reliability professionals can learn from each other through a series of presentations, question & answers sessions, networking opportunities and a selection of full-day workshops. Participants will discover exciting new ideas and learn helpful techniques for maintenance and reliability, predictive maintenance and condition monitoring, and maintenance basics like prioritizing, planning, and scheduling work. IMC-2006 will be held Dec.

By Plant Engineering Staff
Lean Maintenance October 5, 2006

Lean webinar features Womack and Shook

“Lean Management and the Role of Lean Leadership” is the firstJohn Shook, senior advisor to LEI and the first American to work as a manager in Toyota’s operations in Japan, will share the key characteristics of Lean management and leadership as he learned it at Toyota and other companies. The webinar will address where management begins and ends; how value is created for the customer in the three key processes of any business: design, make and use; the links between a Lean Management System and traditional organizational structures; the role of Lean leaders as change agents; the “right" leadership style to support a Lean transformation; and the vital few leadership principles and practices at Toyota. Interested viewers can go to www.lean.org to register for the webinar.

By Plant Engineering Staff
Lean Maintenance August 3, 2006

Why Lean companies stay fat: Lean manufacturing for high performance

Click here for: Why Lean companies stay fat: Lean manufacturing for high performance White Paper Registration Policy By agreeing to register to view this white paper, you agree that we may share your registration information with the white paper sponsor. We do not permit this company to use your personally identifiable information without your permission for any purpose other than to send you information about their own products and services.

By Plant Engineering Staff
Lean Maintenance July 1, 2006

InfraMation 2006 to address predictive maintenance

The InfraMation 2006 Conference, sponsored by Flir, is designed for anyone seeking innovative ways to reduce costs, improve worker safety and optimize productivity by averting shutdowns and extending the life of capital equipment through the use of infrared thermography. Learn from experts in the field as they cover a selection of topics, ranging from predictive maintenance, thermal research an...

By Staff
Lean Maintenance May 1, 2006

Techsolve site offers leaner look at Lean

With the launch of a newly redesigned Website, www.techsolve.org, TechSolve has pulled together educational resources on lean manufacturing and machining optimization. The Website includes detailed descriptions of lean and machining applications in the manufacturing industry, client case studies and video media, a thorough explanation of the benefits and levels of membership, and a calendar and...

By Staff
Lean Maintenance April 11, 2006

Scheduling Not Just A Maintenance Thing

Click here to download the pdf on this article .

By Darrin Wikoff : Life Cycle Engineering
Lean Maintenance March 24, 2006

Welcome to Maintenance Connection!

PLANT ENGINEERING’s Maintenance Connection is a monthly e-newsletter that provides plant and maintenance management with cutting edge ideas to improve maintenance practices in their operation. Each month, we’ll take a look at issues such as maintenance scheduling, safety and reliability, all with the goal of creating value from the maintenance operation. We welcome your suggestions, questions and views on maintenance issues. Contact editor Bob Vavra at BVavra@cfemedia.com and let him know what issues you’d like to see covered in future editions.

By Plant Engineering Staff
Lean Maintenance March 1, 2006

Maintenance e-newsletter debuts on March 24

Maintenance is a crucial issue on the plant floor every day, and PLANT ENGINEERING has added new columns and features each month to keep readers informed about the latest trends and products in the rapidly-changing field. Starting March 24, PLANT ENGINEERING offers Maintenance Connection, our new monthly e-newsletter that brings those issues and features right to your desktop.

By Staff
Lean Maintenance November 1, 2005

Battery vent cap a maintenance aid

Dissipater battery vent cap solves many maintenance problems. A patented design dissipates heat and returns water to the battery during charging. Overflow protection holds expanded acid during recharging, eliminating over-watering. A built-in eye indicates the electrolyte level in every cell. A patented filtration system reduces harmful gases by filtering odors and creating a healthy environment.

By Staff
Lean Maintenance November 1, 2005

Gas analyzer reduces maintenance expense

OxyTrak 411 flue gas oxygen analyzer is self-calibrating and requires no reference air. It uses a miniature zirconium-oxide sensor with a sealed internal reference to determine flue gas oxygen content, even with rapidly changing process conditions. Eliminating the reference air piping greatly simplifies (and reduces the cost of) system installation, while the self-calibrating operation reduces ...

By Staff
Lean Maintenance November 26, 2003

Maintenance work-Part 3

This is the third installment in a three-part article about Maintenance Work. 

By Plant Engineering Staff
Lean Maintenance August 1, 2000

Maintenance Tips & Tricks – 2000 – #8

Terminating wiresProblem: Devices such as switches and receptacles are usually daisy chained to one another to serve multiple locations via a single circuit. What practices are approved to terminate wiring and device connections? Solution: There are three approaches available to perform this task. Approach A uses both terminals of a standard receptacle. Failure of this device can affect other loads downstream on the circuit.

By Plant Engineering Staff
Lean Maintenance March 1, 2000

Maintenance software – 2000-03-01

Ivara.EXP is a rule-based expert system that supports proactive maintenance based on equipment condition information. The software predefines the appropriate maintenance program and monitors the overall condition of critical equipment. Ivara Corp.

By Staff
Lean Maintenance February 1, 2000

Conveyor belts come clean

Eliminator H-Type conveyor belt precleaner strips away carryback residue at the head pulley to keep more material in the product stream and reduce cleanup elsewhere.

By Staff
Lean Maintenance December 1, 1999

Save the solvent

Solventsaver is a filtration/treatment/cleansing system that works with any solvent-based parts cleaner using mineral spirits/petroleum-based products. Solvent life is significantly extended, reducing labor and disposal costs.

By Staff
Lean Maintenance November 1, 1999

Software lets users create maintenance programs

EXP offers full support for RCM methodology, manual and electronic gathering and analysis of equipment condition, and a comprehensive equipment maintenance program that consists of predictive, preventive, and corrective activities.

By Staff
Lean Maintenance October 1, 1999

Predictive maintenance system uses web technology

Field Browser predictive maintenance system uses any web browser and internet computer to enable a user to view the status of all control valves on an easy-to-read screen.

By Staff
Lean Maintenance September 1, 1999

Maintenance Tips & Tricks – 1999 – #4

Bridle the bristles Problem: Cleaning parts in the parts washer is aggravating because the bristles on the standard round brush are standing out in all directions. Solution: Borrow a trick from painters — “bridle” the brush. Take an o-ring a little smaller than the brush diameter and roll it down the bristles to get the desired shape. Contributor : Philip J. Soliday, Freeman Products, Knox, IN; 219-772-2129 List of Tips & Tricks Plant Engineering.

By Plant Engineering Staff
Lean Maintenance June 1, 1999

Pavement maintenance

A 32-p catalog offers a wide selection of asphalt and concrete coatings; crack sealants; line striping, marking, and stenciling products; color surfacing; tools; and safety supplies. Product prices are listed to aid in budgeting. Maintenance, Inc.

By Staff
Lean Maintenance April 1, 1999

Water jet accessories

A 64-p water jet accessory catalog offers nearly 500 items to clean, cut, or prepare surfaces with high-pressure equipment.

By Staff
Lean Maintenance April 1, 1999

MAINTENANCE TOOLSAND EQUIPMENT

James Morton Group, Serpent & DoveMagWand magnetic cleaner

By Staff
Lean Maintenance April 1, 1999

GENERAL AND MAINTENANCE SOFTWARE – 1999-04-01

Datastream Systems, Inc.MP2 Weblink system

By Staff
Lean Maintenance March 1, 1999

Construction and maintenance

A broad range of single-source field construction, maintenance services, and construction management is presented in an 8-p brochure.

By Staff
Lean Maintenance March 1, 1999

Solvent provides alternative to chlorinated cleaners

C/D Solv RE cleaner/degreaser is a rapidly evaporating alternative to chlorinated solvent products. It is fast drying and quickly penetrates to clean grease and grime without leaving a residue.

By Staff
Lean Maintenance October 1, 1998

Hand cleaners attack dirt and soothe hands

Orange Hand Cleaners offer a natural, citrus-based lotion formula to remove the toughest on-the-job dirt and grease without water. A combination of natural moisteners and lotions help protect hands from chapping.

By Staff
Lean Maintenance August 1, 1998

Water cleaning

Equipment to clean with water and clean or dispose of the resultant dirty water is summarized in a 6-p brochure.

By Staff
Lean Maintenance July 1, 1998

Towels offer on-the-spot cleaning

Premoistened hand towels cut through dirt and grime, such as oil, paint, grease, tar, and ink. A wiper and cleaner in one, the rough side of the towels loosen, trap, and retain grime without smearing the soil back onto hands. New Pig Corp. www.newpig.

By Staff
Lean Maintenance June 1, 1998

Maintenance equipment

A broad array of industrial maintenance equipment is presented in a 102-p catalog. Products include tube/pipe cleaners, vacuums/floor machines, pressure washers, and duct cleaners. Numerous photos are provided. Goodway Technologies Corp. www.goodway.com

By Staff
Lean Maintenance May 1, 1998

From maintenance to stewardship

One of the problems with industrial maintenance these days is that it's, well, maintenance. Maintenance by definition means keeping things the way they are (or in original condition), and that won't hack it any more.

By Richard L. Dunn
Lean Maintenance April 1, 1998

Cleaning products

A 36-p catalog presents a line of cleaning items such as wipers, premoistened wipers, surface liners, hand cleaners, degreasers, and personal protection products. Economic dispensing solutions for the products help control consumption and reduce waste.

By Staff
Lean Maintenance April 1, 1998

Wipes treated with flame-resistant coating

Workhorse TR manufactured rags are nonwoven wipes treated with a flame retardant coating that passes NFPA 701 flammability resistance tests. The wipes clean oil, grease, grime, and solvents and are available on rolls of 740.

By Staff
Lean Maintenance March 1, 1998

Hand cleaning towels

Lifter Wipes premoistened towels remove dirt, soil, heavy grease, oils, tar, wax, and adhesives while conditioning and softening hands. There is no need for rinsing or drying. La-Co Industries, Inc. www.laco.markal.industry.net

By Staff
Lean Maintenance March 1, 1998

Hand cleaner towels

Rough Touch Scrubs combine a high-quality, liquid hand cleaner formula with a heavy-duty, nonscratching, abrasive hand-cleaning towel.

By Staff
Lean Maintenance March 1, 1998

Cleaning filters

A portable ultrasonic system for cleaning liquid filter components is described in this bulletin. The system eliminates messy and time-consuming cleaning alternatives, such as pressure washing and steam cleaning. R-P Products

By Staff
Lean Maintenance February 1, 1998

Maintenance tips

A folder features 100 useful and easy-to-understand tips submitted by maintenance and operations department personnel over the last 50 yr. Kano Laboratories Inc.

By Staff
Lean Maintenance February 1, 1998

Ultrasonic filter cleaner works fast

A portable, ultrasonic system for cleaning liquid filter components eliminates the need for pressure washing and steam cleaning. The system cleans reusable sintered, pleated, bonded, slotted, or multi-layered mesh filter media in 5 to 15 min.

By Staff
Lean Maintenance January 1, 1998

Degreaser gel removes hardened films

GRD gelled remover/degreaser is a high-performance product specifically designed for the removal of aged, hard film, corrosion-inhibiting compounds, particularly cured resins, adhesives, and baked-on grease and oil.

By Staff