Published March 30, 2025 | Version CC-BY-NC-ND 4.0
Journal article Open

Achieving Maintenance Excellence in Manufacturing Through Integration of Lean Six Sigma and Proactive Approaches: A Case Study

Authors/Creators

  • 1. Department of Mechanical Engineering, Faculty of Engineering, Shubra, Benha University, Cairo, Egypt.

Description

Abstract: Achieving maintenance excellence is essential for enhancing operational efficiency, reducing unplanned downtime, and maintaining the performance of critical manufacturing systems. This study examines the integration of Lean Six Sigma (LSS) with proactive maintenance strategies—Risk-Based Inspection (RBI), Reliability-Centered Maintenance (RCM), and Total Productive Maintenance (TPM)—to improve equipment reliability, extend asset lifespan, and optimize resource utilization. While LSS targets inefficiencies through continuous improvement, RBI, RCM, and TPM offer data-driven, proactive solutions for minimizing downtime and enhancing system performance. Despite their successes, the combined application of these methodologies in asset management remains largely unexplored. This paper introduces a novel framework that integrates LSS, RBI, RCM, and TPM to optimize asset performance by improving reliability, availability, maintainability, and safety (RAMS), while reducing risks and costs. The framework includes well-defined objectives and key performance indicators (KPIs) to facilitate data-driven decisionmaking and encourage ongoing improvements. Validated through a case study of a major shutdown maintenance project at a feedwater pumping station in a petrochemical company in Egypt, the framework demonstrated significant outcomes, including a 60% reduction in non-value-added time, a 43% decrease in downtime, and a 22% improvement in shutdown efficiency (from 27% to 49%). These results underscore the synergistic potential of integrating LSS, RBI, RCM, and TPM to optimize maintenance practices and enhance operational performance. This study provides valuable insights for both academics and industry professionals seeking to align maintenance strategies with organizational objectives and drive sustainable, long-term improvements.

Files

B109912020225.pdf

Files (1.7 MB)

Name Size Download all
md5:7b7b3c12fc9e50e5e3e2f696f675fbef
1.7 MB Preview Download

Additional details

Identifiers

DOI
10.35940/ijies.B1099.12030325
EISSN
2319-9598

Dates

Accepted
2025-03-15
Manuscript received on 24 January 2025 | First Revised Manuscript received on 30 January 2025 | Second Revised Manuscript received on 16 February 2025 | Manuscript Accepted on 15 March 2025 | Manuscript published on 30 March 2025.

References

  • Gomaa, A.H., 2022. Enhancing maintenance management of critical equipment using digital twin. Comprehensive Research and Reviews in Engineering and Technology, (CRRET), 1(1), pp.45-55. DOI: https://doi.org/10.57219/crret.2022.1.1.0025
  • Antosz, K., Pasko, L. and Gola, A., 2020. The use of artificial intelligence methods to assess the effectiveness of lean maintenance concept implementation in manufacturing enterprises. Applied Sciences, 10(21), p.7922. DOI: https://doi.org/10.3390/app10217922
  • Gomaa, A.H., 2024. Improving Shutdown Maintenance Management Performance Using Lean Six Sigma Approach: A Case Study. International Journal of Applied and Physical Sciences, IJAPS, 10(1), pp.1-14. https://kkgpublications.com/applied-sciences-v10-article1/
  • Gomaa, A.H., 2024. Enhancing proactive maintenance of critical equipment by integrating digital twins and lean six sigma approaches. International Journal of Modern Studies in Mechanical Engineering (IJMSME) Volume 10, Issue 1, 2024, PP 20-35. https://www.arcjournals.org/pdfs/ijmsme/v10-i1/3.pdf
  • Herrera-Barreda, I., 2024. Enhancing operational efficiency in textile SMEs: Integrating lean manufacturing and total productive maintenance for superior performance. 5th Asia Pacific Conference on Industrial Engineering and Operations Management Tokyo, Japan, September 10-12, 2024. https://ieomsociety.org/proceedings/2024tokyo/101.pdf
  • Abdallah, A.M., Atadero, R.A. and Ozbek, M.E., 2022. A state-of-theart review of bridge inspection planning: current situation and future needs. Journal of Bridge Engineering, 27(2), p.03121001. https://ascelibrary.org/doi/abs/10.1061/(ASCE)BE.1943-5592.0001812
  • Babaeian, A., Eslami, A., Ashrafizadeh, F., Golozar, M.A., Samadzadeh, M. and Abbasian, F., 2023. Risk-based inspection (RBI) of a gas pressure reduction station. Journal of Loss Prevention in the Process Industries, 84, p.105100. DOI: https://doi.org/10.1016/j.jlp.2023.105100
  • Javid, Y.J.P.S., 2021. A bi-objective mathematical model to determine risk-based inspection programs. Process Safety and Environmental Protection, 146, pp.893-904. DOI: https://doi.org/10.1016/j.psep.2020.12.022
  • Song, J.S., Lok, V., Yoon, K.B., Ma, Y.W. and Kong, B.O., 2021. Quantitative risk-based inspection approach for high-energy piping using a probability distribution function and modification factor. International Journal of Pressure Vessels and Piping, 189, p.104281. DOI: https://doi.org/10.1016/j.ijpvp.2020.104281
  • Afefy, I.H., Mohib, A., El-Kamash, A.M. and Mahmoud, M.A., 2019. A new framework of reliability centered maintenance. Jordan Journal of Mechanical & Industrial Engineering, 13(3). https://jjmie.hu.edu.jo/vol13-3/88-19-01.pdf
  • Alrifaey, M., Sai Hong, T., As' arry, A., Elianddy Supeni, E. and Ang, C.K., 2020. Optimization and selection of maintenance policies in an electrical gas turbine generator based on the hybrid reliability-centered maintenance (RCM) model. Processes, 8(6), p.670. DOI: https://doi.org/10.3390/pr8060670
  • da Silva, R.F., Melani, A.H.D.A., Michalski, M.A.D.C. and de Souza, G.F.M., 2023. Reliability and Risk Centered Maintenance: A novel method for supporting maintenance management. Applied Sciences, 13(19), p.10605. DOI: https://doi.org/10.3390/app131910605
  • Enjavimadar, M. and Rastegar, M., 2022. Optimal reliability-centered maintenance strategy based on the failure modes and effect analysis in power distribution systems. Electric Power Systems Research, 203, p.107647. DOI: https://doi.org/10.1016/j.epsr.2021.107647
  • Liu, Y., Tang, Y., Wang, P., Song, X. and Wen, M., 2023. Reliabilitycentered preventive maintenance optimization for a single-component mechanical equipment. Symmetry, 16(1), p.16. DOI: https://doi.org/10.3390/sym16010016
  • Prasetyo, Y.T. and Rosita, K.K.M., 2020, September. Equipment reliability optimization using predictive reliability centered maintenance: a case-study illustration and comprehensive literature review. In 2020 7th International Conference on Frontiers of Industrial Engineering (ICFIE) (pp. 93-97). IEEE. https://ieeexplore.ieee.org/abstract/document/9266728
  • Shamayleh, A., Awad, M. and Abdulla, A.O., 2020. Criticality-based reliability-centered maintenance for healthcare. Journal of Quality in Maintenance Engineering, 26(2), pp.311-334. DOI: http://doi.org/10.1108/JQME-10-2018-0084
  • Ardi, M., Sutanto, A. and Susilawati, A., 2023. Analysis of effectiveness of cut size line machines based on total productive maintenance (TPM) and analytical hierarchy process (AHP)-A case study. Journal of Ocean, Mechanical and Aerospace-science and engineering-, 67(3), pp.109-117. DOI: http://dx.doi.org/10.36842/jomase.v67i3.351
  • Flagg, M.I. and Amadi, N.S., 2024. Utilization of total productive maintenance techniques for quality improvement of electrical workshop by technical colleges in Rivers State. International Journal of Modern Innovations and Knowledge, 5(2), pp.1-11. https://ijmik.net/index.php/ijmik/article/view/120
  • Gelaw, M.T., Azene, D.K. and Berhan, E., 2024. Assessment of critical success factors, barriers and initiatives of total productive maintenance (TPM) in selected Ethiopian manufacturing industries. Journal of Quality in Maintenance Engineering, 30(1), pp.51-80. DOI: https://doi.org/10.1108/JQME-11-2022-0073
  • Meza Jiménez, J., Cárdenas Velasco, H.E., Escamilla López, M. and Quintana Alvarado, J., 2024. Total productive maintenance (TPM). Lean Manufacturing in Latin America: Concepts, Methodologies and Applications, pp.263-284. https://link.springer.com/chapter/10.1007/978-3- 031-70984-5_12
  • Mohad, F.T., Gomes, L.D.C., Tortorella, G.D.L. and Lermen, F.H., 2024. Operational excellence in total productive maintenance: Statistical reliability as support for planned maintenance pillar. International Journal of Quality & Reliability Management. DOI: https://doi.org/10.1108/IJQRM-09-2023-0290
  • Samadhiya, A. and Agrawal, R., 2024. Total productive maintenance and sustainability performance: resource-based view perspective. Benchmarking: An International Journal, 31(7), pp.2177-2196. DOI: https://doi.org/10.1108/BIJ-10-2022-0635
  • Sangel, R.O., Pablo, A.D., Eboras, A.V. and Namoco Jr, C.S., 2024. Potential of implementing total productive maintenance (TPM) on a smallscale machine shop. Journal of Harbin Engineering University, 45(9), pp.150-156. https://hal.science/hal-04733983/
  • Al Farihi, A.H., Sumartini, S. and Herdiman, L., 2023. Designing lean maintenance using total productive maintenance method–a case study at wiring harness production. In E3s web of conferences (Vol. 465, p. 02016). EDP Sciences. DOI: https://doi.org/10.1051/e3sconf/202346502016
  • Imanov, T., Yildiz, M. and Koruyucu, E., 2021. Application and development of aircraft maintenance procedures using lean tools. In International symposium on aircraft technology, MRO & Operations, ISATECH-2021, Budapest, Hungary, pp. 1-3. https://www.researchgate.net/publication/366946733
  • Hassan, M.N., Barakat, A.F. and Sobh, A.S., 2020, July. Effect of applying lean maintenance in oil and gas fields. In The international conference on applied mechanics and mechanical engineering (Vol. 19, No. 19th International Conference on Applied Mechanics and Mechanical Engineering., pp. 1-13). DOI: http://doi.org/10.1088/1757- 899X/973/1/012045
  • Aditiyawarman, T., Kaban, A.P.S. and Soedarsono, J.W., 2023. A recent review of risk-based inspection development to support service excellence in the oil and gas industry: an artificial intelligence perspective. ASCE-ASME Journal of Risk and Uncertainty in Engineering Systems, Part B: Mechanical Engineering, 9(1), p.010801. DOI: https://doi.org/10.1115/1.4054558
  • Hameed, H., Bai, Y. and Ali, L., 2021. A risk-based inspection planning methodology for integrity management of subsea oil and gas pipelines. Ships and offshore structures, 16(7), pp.687-699. DOI: https://doi.org/10.1080/17445302.2020.1747751
  • Liu, G., Liu, L., Li, Q., Wang, Q. and Zhang, H., 2024, August. Reliability-Centered Maintenance Scheduling Optimization for High-Speed Railway Facilities with Multi-level Tasks. In International Conference on Traffic and Transportation Studies (pp. 51-60). Singapore: Springer Nature Singapore. https://link.springer.com/10.1007/978-981-97-9644- 1_6
  • Asghari, A. and Jafari, S.M., 2024. Investigating the Influence of reliability centered maintenance on water treatment plant pumps (Case study: Guilan water treatment plant). Journal of Water and Wastewater; Ab va Fazilab (in persian), 35(1), pp.86-102. https://www.wwjournal.ir/article_198392.html?lang=en
  • Biswas, J., 2024. Total productive maintenance: an in-depth review with a focus on overall equipment effectiveness measurement. International Journal of Research in Industrial Engineering, 13(4), pp.376-383. DOI: http://doi.org/10.22105/riej.2024.453380.1436
  • Shannon, N., Trubetskaya, A., Iqbal, J. and McDermott, O., 2023. Atotal productive maintenance & reliability framework for an active pharmaceutical ingredient plant utilising design for Lean Six Sigma. Heliyon, 9(10). DOI: https://doi.org/10.1016/j.heliyon.2023.e20516
  • Trubetskaya, A., Ryan, A., Powell, D.J. and Moore, C., 2023. Utilising a hybrid DMAIC/TAM model to optimise annual maintenance shutdown performance in the dairy industry: a case study. International Journal of Lean Six Sigma, 15(8), pp.70-92. DOI: https://doi.org/10.1108/IJLSS05-2023-0083
  • Arsakulasooriya, K.K., Sridarran, P. and Sivanuja, T., 2024. Applicability of lean maintenance in commercial high-rise buildings:Acase study in Sri Lanka. Facilities, 42(3/4), pp.342-357. DOI: https://doi.org/10.1108/F-10-2022-0131
  • Torre, N.M.D.M. and Bonamigo, A., 2024. Action research of lean 4.0 application to the maintenance of hydraulic systems in steel industry. Journal of Quality in Maintenance Engineering, 30(2), pp.341-366. DOI: https://doi.org/10.1108/JQME-06-2023-0058
  • Mohammadi, A., Igwe, C., Amador-Jimenez, L. and Nasiri, F., 2022. Applying lean construction principles in road maintenance planning and scheduling. International journal of construction management, 22(12), pp.2364-2374. DOI: https://doi.org/10.1080/15623599.2020.1788758
  • Singha Mahapatra, M. and Shenoy, D., 2022. Lean maintenance index: a measure of leanness in maintenance organizations. Journal of Quality in Maintenance Engineering, 28(4), pp.791-809. DOI: https://doi.org/10.1108/JQME-08-2020-0083
  • Shou, W., Wang, J., Wu, P. and Wang, X., 2021. Lean management framework for improving maintenance operation: Development and application in the oil and gas industry. Production Planning & Control, 32(7), pp.585-602. DOI: https://doi.org/10.1080/09537287.2020.1744762
  • Antosz, K., Jasiulewicz-Kaczmarek, M., Paśko, Ł., Zhang, C. and Wang, S., 2021. Application of machine learning and rough set theory in lean maintenance decision support system development. Eksploatacja i Niezawodność, 23(4), pp.695-708. DOI: http://dx.doi.org/10.17531/ein.2021.4.12
  • Bakri, A., Alkbir, M.F.M., Awang, N., Januddi, F., Ismail, M.A., Ahmad, A.N.A. and Zakaria, I.H., 2021. Addressing the issues of maintenance management in SMEs: towards sustainable and lean maintenance approach. Emerg. Sci. J, 5, pp.367-379. DOI: http://dx.doi.org/10.28991/esj-2021-01283
  • Karunakaran, S., 2016. Innovative application of LSS in aircraft maintenance environment. International journal of lean six sigma, 7(1), pp.85-108. DOI: https://doi.org/10.1108/IJLSS-01-2015-0001
  • Yang, D.Y. and Frangopol, D.M., 2021. Risk-based inspection planning of deteriorating structures. Structure and Infrastructure Engineering, 18(1), pp.109-128. DOI: https://doi.org/10.1080/15732479.2021.1907600
  • Javid, Y., 2025. Efficient risk-based inspection framework: Balancing safety and budgetary constraints. Reliability Engineering & System Safety, 253, p.110519. DOI: https://doi.org/10.1016/j.ress.2024.110519
  • Almeida de Rezende, F., Videiro, P.M., Volnei Sudati Sagrilo, L., de Oliveira, M.C. and dos Santos, G.Y.M., 2024, June. A tool for reliabilitybased inspection planning of mooring chains. In International Conference on Offshore Mechanics and Arctic Engineering (Vol. 87790, p. V002T02A036). American Society of Mechanical Engineers. DOI: https://doi.org/10.1115/OMAE2024-123451
  • Huang, Y., Qin, G. and Yang, M., 2023. A risk-based approach to inspection planning for pipelines considering the coupling effect of corrosion and dents. Process Safety and Environmental Protection, 180, pp. 588- 600. DOI: https://doi.org/10.1016/j.psep.2023.10.025
  • Zhang, W.H., Qin, J., Lu, D.G., Liu, M. and Faber, M.H., 2023. Quantification of the value of condition monitoring system with time-varying monitoring performance in the context of risk-based inspection. Reliability Engineering & System Safety, 231, p.108993. DOI: https://doi.org/10.1016/j.ress.2022.108993
  • Eskandarzade, M., Shahrivar, R., Ratnayake, R.C. and Bukhari, U.N., 2022. An optimal approach for semiquantitative risk-based inspection of pipelines. Journal of Pipeline Systems Engineering and Practice, 13(3), p.04022017. DOI: https://doi.org/10.1061/(ASCE)PS.1949- 1204.0000653
  • Sözen, L., Yurdakul, M. and Ic, Y.T., 2022. Risk-based inspection planning for internal surface defected oil pipelines exposed to fatigue. International Journal of Pressure Vessels and Piping, 200, p.104804. DOI: https://doi.org/10.1016/j.ijpvp.2022.104804
  • Agistina, A., Budiasih, E. and Pramoso, A., 2021, February. Determination of risk Level, remaining life prediction, and risk based inspection planning based on API 581. In IOPConference Series: Materials Science and Engineering (Vol. 1034, No. 1, p. 012116). IOP Publishing. DOI: http://doi.org/10.1088/1757-899X/1034/1/012116
  • Abubakirov, R., Yang, M. and Khakzad, N., 2020. A risk-based approach to determination of optimal inspection intervals for buried oil pipelines. Process Safety and Environmental Protection, 134, pp.95-107. DOI: https://doi.org/10.1016/j.psep.2019.11.031
  • Rachman, A. and Ratnayake, R.C., 2018, June. Artificial neural network model for risk-based inspection screening assessment of oil and gas production system. In ISOPE International Ocean and Polar Engineering Conference (pp. ISOPE-I). ISOPE. https://onepetro.org/ISOPEIOPEC/proceedings-abstract/ISOPE18/All-ISOPE18/20562
  • Arzaghi, E., Abaei, M.M., Abbassi, R., Garaniya, V., Chin, C. and Khan, F., 2017. Risk-based maintenance planning of subsea pipelines through fatigue crack growth monitoring. Engineering Failure Analysis, 79, pp.928-939. DOI: https://doi.org/10.1016/j.engfailanal.2017.06.003
  • Kamsu-Foguem, B., 2016. Information structuring and risk-based inspection for the marine oil pipelines. Applied Ocean Research, 56, pp.132-142. DOI: https://doi.org/10.1016/j.apor.2016.01.009
  • Febriyana, P., Haryadi, G.D., Widodo, A., Tauviqirrahman, M., Suprihanto, A., Adigama, A.S., Susilo, D.D. and Kim, S.J., 2019, April. Evaluation for detecting and monitoring of offshore pipeline damage based on risk based inspection method. In AIP Conference Proceedings (Vol. 2097, No. 1). AIP Publishing. DOI: https://doi.org/10.1063/1.5098261
  • Melo, C., Dann, M.R., Hugo, R.J. and Janeta, A., 2019. A framework for risk-based integrity assessment of unpiggable pipelines subject to internal corrosion. Journal of Pressure Vessel Technology, 141(2), p.021702. DOI: https://doi.org/10.1115/1.4042350
  • Ali Ahmed Qaid, A., Ahmad, R., Mustafa, S.A. and Mohammed, B.A., 2024. A systematic reliability-centred maintenance framework with fuzzy computational integration–A case study of manufacturing process machinery. Journal of Quality in Maintenance Engineering, 30(2), pp.456-492. DOI: https://doi.org/10.1108/JQME-04-2022-0021
  • Cahyati, S., Puspa, S.D., Himawan, R., Agtirey, N.R. and Leo, J.A., 2024. Optimization of preventive maintenance on critical machines at the Sabiz 1 plant using reliability-centered maintenance method. Sinergi (Indonesia), 28(2), pp.355-368. DOI: http://doi.org/10.22441/sinergi.2024.2.015
  • Sembiring, A.C., 2024. Analysis of boiler machine maintenance using the reliability-centered maintenance method. JKIE (Journal Knowledge Industrial Engineering), 11(1), pp.1-8. https://jurnal.yudharta.ac.id/v2/index.php/jkie/article/view/5004
  • Al-Farsi, N. and Syafiie, S., 2023, April. Reliability centered maintenance application for the development of maintenance strategy for a chemical plant. In International Conference on Mathematical and Statistical Physics, Computational Science, Education, and Communication (ICMSCE 2022) (Vol. 12616, pp. 211-214). SPIE. https://doi.org/10.1117/12.2675549
  • Introna, V. and Santolamazza, A., 2024. Strategic maintenance planning in the digital era: A hybrid approach merging Reliability-Centered Maintenance with digitalization opportunities. Operations Management Research, pp.1-24. https://link.springer.com/article/10.1007/s12063- 024-00496-y