Lean Maintenance model to reduce scraps and WIP in manufacturing system:case study in power cables factory

The aim of this paper is to develop an innovative Lean Maintenance model in order to optimize the process flow and reduce or eliminate scraps and work-in-progress (WIP) in a manufacturing context. To achieve these objectives has been formulated a new method, called Lean Root Cause & Defect Analysis (LRCDA), which merges the process steps of the existing Root Cause & Failure Analysis (RCFA) technique and basic principles of Lean Maintenance and Total Productive Maintenance (TPM).The LRCDA is a logical sequence of phases the leads the investigator through the process of isolating the facts surrounding the event or the fault. After the problem defining, the analysis determines the best actions, corrective and preventive, to will resolve the problem and its recurrence. The model has been implemented for the first time in a power cables factory with intent to reduce the partial discharges phenomena in medium voltage (MV) cables. Key-Words: lean maintenance, total productive maintenance, maintenance-production relationship, autonomous maintenance, root cause & failure analysis.