Application of Lean Six Sigma Techniques to the Management and Maintenance of Special Lifting Equipment

This paper describes the application of Lean Six Sigma techniques in an energy technology company that provides solutions for energy and industrial customers worldwide. It outlines the systematic, step-by-step application of the Define, Measure, Analyze, Improve, and Control (DMAIC) in the management and maintenance of special lifting equipment. Special lifting equipment and assembly aids are required to place/remove machines, systems, machine parts, and system parts in/from locations that are difficult to access, to move them using crane systems, to secure them tightly when transporting to prevent hazards, to protect people and materials, and to guarantee that work is carried out economically and in a time-saving manner. These equipment are essential in carrying out production activities within the factory, and also fall within the essential health and safety requirements of the Machinery Directive 2006/42/EC, thus having to comply with legal obligations and be accompanied by related documentation and procedures. Implementing DMAIC involved process mapping methods and rigorous data collection. Root cause analysis and Pareto diagrams were applied to track and archive the manuals of use and maintenance and the EC Declaration of Conformity. In addition, a procedural standard was created regarding the transfer of equipment from suppliers and the delivery to the internal warehouses. Maintenance audits are also reported and examples of recertification and disposal are illustrated. The application of proper tools and methods helped to identify, evaluate and mitigate risks, and to reduce the complexity of risk management, and improved the company's operational performance maintaining, at the same time, a safe work environment.