Application of Lean Six Sigma for Maintenance: Case Study

Reducing downtime of maintenance processes remains a constant goal of production companies. The elimination of unexpected failures that might generate excessive costs and production losses is emphasized. The article presents the possibility of using the Lean Six Sigma tools to reduce the downtime of the maintenance processes. For this purpose, the DMAIC approach was used to analyze the automotive company’s case study. Firstly, the problem was defined. Secondly, the key performance indicator was measured. Thirdly, the data was analyzed to define the root causes. Fourthly, action plans were implemented to improve the maintenance process. Finally, a cost-benefit analysis was held to control the improvement. Meanwhile, the maintenance function was assessed by an Audit Yves Lavina. This audit is based on a questionnaire that helps to analyze the maintenance function entirely. The radar diagram illustrated the low satisfaction rates; which led to the implementation of improvement actions.