World-Class, Lean Performance in the SMEs - Small and Medium Enterprises - by Carlo Scodanibbio, Industrial & Business Consultant - Lean Management Consultant

Carlo Scodanibbio
Industrial & Business Consultant
Lean Management Consultant

training course program

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Training Course Program
Lean Maintenance & Lean Plant Management - 3-day course
what has to be changed in the traditional approach to maintenance operations and plant/assets management in order to face the challenges of the years 2000

"We are what we repeatedly do. Excellence, therefore, is not an act, but a habit. Aristotle"

course contents and main topics

course duration

Duration: 24 hours (typical)

course objectives

Dear Delegate(s),

Maintenance. It has been officially invented and structured as a plant management discipline over 60 years ago.
Technically, it has gone through many and major changes: maintenance techniques have been improved, modified, widened and new maintenance techniques have been discovered over the last 2 decades. Organisationally, however, maintenance has only somewhat changed with the advent of Nakajima's TPM - Total Productive Maintenance. Today, maintenance is changing again. Today, we discover that "maintenance" does not always deliver what it promises: plant, machinery and equipment operating efficiently and effectively along their entire lifecycle and at the least possible total cost.
The signals are clear and well known: major breakdowns still materialise in spite of excellent preventive maintenance and even autonomous maintenance practices - minor breakdowns, minor stoppages, idling, reduced-capacity operation, quality defectiveness and other malfunctions are still present in the majority of factories and plants world-wide in spite of efforts and investments to reduce them considerably - maintenance costs are still too high for the level of competitiveness required nowadays - waste (of maintenance manpower, of materials, of operation time) is at un-acceptable levels - large maintenance works and yearly shut-down projects are seldom completed in time and within budget - outage maintenance often becomes panic management.
There is a common denominator to all signals above: inadequate project management and inadequate planning - that is, inadequate thinking. Most maintenance works - even routine, scheduled maintenance activities - ARE project works by their own nature and as such should be handled. However, project management practices are only dedicated (when it so happens!) to large-scale maintenance works and with doubtful effectiveness. Project Management and, even less, Lean Project Management, are hardly known to maintenance people at ALL levels. That's what is lacking.
The real revolution in the maintenance world is taking place only now. Under the Lean Thinking philosophy, lean principles can and should be deployed also in maintenance activities and made known to all those concerned, including maintenance technicians and workers.

This course will be a shocking course for many of you. Because it demystifies all traditional principles of the first industrial revolution on which the majority of enterprises, still today, are built or around which they operate. By presenting in rather great detail the philosophy of the second industrial revolution applied to the maintenance world and the main tools and disciplines readily available to all enterprises to perform in an "excellent" status, this course is a door-opener to lean maintenance practices for whoever is: ready to listen to message - prepared to abandon obsolete principles, formulas and approaches - willing to get to "lean" status.

By showing that "thinking" is what must change at all levels in the maintenance domain, this course will prove that higher levels of performance can be achieved if you create the right conditions.
I hope to see you there, best regards

Dr Carlo

Specific objectives of this course are:
- Understand the basics of modern Maintenance and Plant Management and the Lean Thinking philosophy, performance goals and critical success factors
- Understand the real reasons of failure of maintenance operations managed and planned with a "traditional" style
- Trigger a different thinking mechanism suited to focus onto crucial issues of the planning process
- Use lean ideas to see maintenance works as "waste-less flow processes" and to think about improvement of the whole maintenance function
- Equip your toolbox with lean planning tools, tips and techniques
- Learn how to ensure Maintenance works of any size/scale will be accomplished in time, within budget and with overall satisfaction
- Understand the difference between traditional Plant Management and Lean Plant/Assets Management
- Learn how to transmit lean concepts to your own people and to external parties such as maintenance sub-contractors
- Implement strategies to increase Plant Performance through lean-thinking people while assuring their job satisfaction

This course is very interactive and supplemented with abundant practical exercises and case studies
This course is equally beneficial for all Industrial Sectors (Manufacturing Industry - Continuous Process Industry - Construction Industry - Service Establishments - Engineering) and for Public/Governmental and semi-Public Bodies and Institutions active in all sizes Maintenance works.
"This is a very thorough and comprehensive programme on all aspects of lean principles deployed in the maintenance and plant management domains"

target audience

- Heads and Directors of Operations, Maintenance and Production
- Operations Managers, Maintenance Managers
- Reliability Engineers, Production Managers or Engineers
- Maintenance Supervisors, Maintenance Planners, Schedulers and Controllers
- Plant Managers/Assets Managers
- Engineering Managers or Chief Engineers
- Project and Shutdown Managers / Leaders / Planners / Coordinators


You are welcome to request further clarifications about this course - please be as specific as possible. Just contact Carlo Scodanibbio

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