Lean Maintenance Management
Apply Lean thinking to maintenance and move toward zero downtime. The course covers maintenance policies and KPIs, breakdown analysis, criticality, autonomous maintenance and CILT, skills matrices, maintenance information and spare-parts systems; the extended format adds CMMS / SAP PM.
At a glance
- 4–5 days · Core ( 35 h)
- 6 days · With CMMS / SAP PM
Who it's for
- Production managers, engineers & supervisors
- Maintenance managers, engineers & supervisors
Learning objectives
- Apply Lean thinking to maintenance to move toward zero downtime
- Set maintenance vision, policies and KPIs
- Analyse breakdowns (5 Why, 4M) and classify equipment
- Implement autonomous maintenance and CILT
- Build maintenance information and spare-parts systems
- Improve production–maintenance communication
Detailed content
- Lean introduction
- Maintenance vision & mission
- Maintenance policies
- Breakdown deployment
- ABC criticality classification
- 5 Why & 4M
- OEE
- Autonomous maintenance steps; abnormality tagging
- CILT (clean, inspect, lubricate, tighten)
- Assessing planned-maintenance cost & performance
- Predictive maintenance technologies
- Work-order cycle & types
- Maintenance information system
- Spare-parts management system
- Maintenance KPIs (MTBF, MTTR, availability)
- Skill matrix & OPL
- Daily maintenance meeting
- CMMS / SAP PM introduction
- Implementation action plan
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Foundations
- Analysis
- Autonomous & Planned Maintenance
- Systems
- CMMS & Action Plan (6-day format)
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Waste walk (gemba) using the 8-waste checklist
- Lean simulation game: push vs. pull, before and after improvement
- Plan a one-week Kaizen event with targets and team roles
- Calculate OEE and the six big losses from a real machine log
Tools and templates you keep
- 8-waste observation sheet
- Kaizen event charter and newspaper (action list)
- Standard work and SMED analysis sheets
- OEE calculator (Excel)
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- Lean Enterprise Institute principles (Womack & Jones)
- Toyota Production System
- JIPM TPM pillars
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Maintenance, Engineering & Reliability · Practitioner
Frequently asked questions
How long is Lean Maintenance Management?
The program runs 4–5 days; other formats: 6 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
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Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.