Food manufacturer conducts kaizen event to establish new maintenance program

A kaizen event was planned with maintenance managers across multiple facilities in order to improve the preventative maintenance (PM) program. Critical equipment was not being consistently tracked and updated, which was leading to unplanned equipment downtime, which has resulted in over $100K in lost output.

There were 81 PM plans active in the system prior to the event in only 3 of the facilities. The 3 day kaizen event included some training on the new PM system, identifying critical equipment at each facility, upload data into the system, and setting up the schedule for those equipment.

At the end of the event, there were 220 new PMs added to the system, with the rest being completed within 30 days of the end of the event.