ABSTRACT
This is the last of the 12 manufacturing principles that I group under the category of infrastructure because good maintenance (i.e., reliable equipment) is so critical to achieving and sustaining excellence. Plants that run machines to failure will be stuck in Stage 1 hell for eternity. I have never understood the mentality of maintenance managers who tolerated (and in some cases even led) this approach. It always takes longer and costs a lot more to deal with a breakdown. Unfortunately, the maintenance crew is typically known for its heroics in being able to jury-rig something to make the machine run. They are among the best firefighters in the plant (along with the expeditors), and they love the exhilaration and the recognition they get over the years. Many probably have Superman tights on under their work clothes. But make no mistake in this day and age: The maintenance department’s function is to prevent breakdowns-plain and simple. There are no rewards or praise for having to react to breakdowns. There is absolutely no ambiguity on who owns Principle 4. If the maintenance manager does not step up, then the plant manager needs to be in the market for a new one.
