Manufacturer Decreased Preventive Maintenance Start Time By 50% With GLSS
Illinois
Manufacturing
Operations
50%
- The problem: In the fast-paced world of manufacturing, every minute counts. Preventive maintenance (PM) is critical for keeping machines running smoothly, but inefficiencies in the process can cause costly delays. For one manufacturer, a common issue was slowing down maintenance teams and causing unnecessary frustration.
- The organization turned to GLSSâs Lean Six Sigma Green Belt Training & Certification, known for its clear, engaging instructional design that helps teams implement effective solutions quickly.
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Manufacturing depends on efficient, well-planned maintenance to keep production lines moving. Any delay in preventive maintenance can lead to lost production time, higher costs, and frustrated employees. One of the biggest hurdles this company faced was the time it took to gather supplies for preventive maintenance. Instead of diving straight into their work, maintenance teams wasted valuable time collecting tools and materials from different parts of the facility.
This inefficiency wasnât just an inconvenienceâit was a major obstacle to keeping operations running smoothly. Without a streamlined system, delays piled up, impacting production schedules and increasing labor costs. To stay competitive, the company needed a process improvement solution that would eliminate wasted time and increase efficiency without overburdening employees.
After analyzing the issue, the company identified three main reasons why the PM supply collection process was so slow:
- Shared Supplies Across Departments: Maintenance staff often had to track down supplies that were also used by other teams.
- No Centralized Storage: There was no single, organized location where all PM supplies were stored.
- Scattered Storage Areas: Supplies were kept in various locations throughout the facility, forcing employees to spend unnecessary time walking back and forth.
With guidance from GLSS Green Belt Training & Certification, the team tackled the problem head-on. The solution? A centralized storage system for all preventive maintenance supplies. By designating a single, easily accessible location, employees no longer had to waste time searching multiple areas. This simple yet powerful change transformed the maintenance workflow, making the entire process more organized, efficient, and stress-free.
The impact of this improvement was immediate and significant:
- 50% reduction in time spent gathering supplies, from 17.8 to 8.9 minutes
- Faster and smoother PM processes
- Reduced employee frustration and increased job satisfaction
With less time spent on prep work, maintenance teams could focus on what truly matteredâkeeping equipment running at peak performance. The company not only improved productivity but also created a more efficient and supportive work environment for its employees.
with GLSS
This project is a prime example of how small, focused process improvements can lead to big results. By leveraging GLSS Training & Certificationâs innovative approach, the organization was able to identify inefficiencies, implement an effective solution, and see measurable improvements in record time.
The combination of clear, structured training and real-world application made all the difference, ensuring that the company achieved faster results and set the stage for continued operational success in the competitive manufacturing industry.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
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