An investigation into the applicability of lean thinking in an operational maintenance environment

[摘要] ENGLISH ABSTRACT: It has been postulated that lean thinking principles can be successfully applied to any industry. Following on that postulation, there have been great advances in the area of lean thinking outside the 'traditional domain of manufacturing. One such advancement has been in the area of maintenance operations where lean thinking has been used through the concept of lean maintenance. However, a problem lies in the fact that the work that has been done so far has been largely limited to the manufacturing environment where lean maintenance is practised as a prerequisite for lean manufacturing. Little evidence exists of the use of frameworks or models that can test, let alone apply, lean thinking in operational maintenance environments outside of the manufacturing context.The main objective of this research was to come up with a framework, based on lean thinking tools and relevant performance measures, which will prove the applicability or otherwise, of lean thinking in an operational maintenance environment outside the traditional domain of manufacturing. A case study of the rolling stock section of the Salt River depot of PRASA, Metrorail, which is a typical non-traditional domain for lean thinking, was used to build and verify the framework. The Analytic Hierarchy Process (AHP) together with the Quality Function Deployment (QFD) process, is used in building and quantifying the judgements made in developing elements of the framework. The Value Stream Management process is used to predict the possible outcomes of using the proposed framework in the case study. The study was based on the hypothesis that lean thinking can also be applicable to non-manufacturing oriented maintenance organisations. The ensuing framework is used to make the argument for the use of the lean thinking approach in non-manufacturing oriented maintenance environments and hence expand the body of knowledge in this subject area. It also provides a roadmap for PRASA, Metrorail and other similar maintenance organisations in the rail industry to streamline and improve current operations through value addition and waste elimination efforts.

[发布机构] Stellenbosch University