Effect of lean maintenance to reduce cost of sugar firms

Maintenance plans are crucial for enhancing the operational efficiency of technological advancements and global competitiveness. This study focuses on improving efficiency and productivity in the refined sugar industry, specifically at Pabrik Gula Rafinasi (PGR). Refined sugar plants often struggle with maintaining equipment properly, which impacts the raw material processing sector. The proposed approach uses Lean Maintenance techniques to enhance maintenance efficiency and effectiveness by eliminating waste, improving processes, and enhancing quality. Lean Maintenance aims to thoroughly examine maintenance processes, identify waste areas, and implement relevant changes. The research has two primary objectives: first, to apply the maintenance concept at PGR to improve overall maintenance performance and streamline the maintenance procedure; second, to optimize the maintenance process using Lean Maintenance techniques to increase efficiency and responsiveness to production demands. The study found that by implementing alternative solutions using smart tools, maintenance costs can be reduced by 4% and maintenance time can be accelerated by 42%. These improvements address three types of waste: transportation (remote tool storage from the toolroom to the production area), transportation (technicians repeatedly borrowing measuring tools), and motion (technicians searching for suitable tools). The understanding and application of Lean Maintenance principles in the refined sugar industry, particularly at PGR, have practical implications. This research offers recommendations and guidance for similar businesses aiming to enhance their maintenance performance. Consequently, this study significantly contributes to the advancement of the refined sugar sector and the discipline of maintenance management.