Toyota Kata’s approach for implementing Lean Maintenance: an action research study

Purpose This study aims to present a novel and flexible systematic method of Lean Maintenance designed to develop solutions and foster scientifically sustainable maintenance excellence. The method integrates the five Lean principles with short plan-do-check-act cycles promoted by the Toyota Kata approach to establish sequential target conditions. This systematic method highlights the active involvement of maintenance process executors in creating sustainable improvements. Design/methodology/approach The proposed systematic method was applied through action research in a thermoplastics manufacturing company. The research team conducted the daily routine of Improvement Kata and Coaching Kata, and employees took part in the initiative. The results were assessed from the perspective of analyzing the improvement process with the team and the benefits for performance indicators. Findings From the point of view of the company, the systematic method promoted problem-solving by strengthening the learning capacity developed through formalizing the maintenance sector’s learning. There was an increase in the machines’ Overall Equipment Effectiveness through improvements such as implementing Total Productive Maintenance, strengthening the 5S program and reducing the setup process. In addition, there was a change in how those involved in the process think by conducting small improvement cycles, which began to direct efforts and promote reflection on the results obtained with each action taken. Originality/value While many companies face challenges in implementing Lean Maintenance due to the absence of a systematic and participatory approach, this study makes an original contribution by offering a replicable pathway that bridges theory and practice. The proposed method stands out for its flexibility, scalability and emphasis on the active involvement of shop-floor personnel, features that distinguish it from conventional top-down implementations. Furthermore, this work addresses a gap in the literature by formalizing a structured improvement routine in maintenance environments aligned with the Lean philosophy.