Preventive Maintenance, Reimagined
A Lean specialist used Power Belt's SMED module to cut preventive maintenance time by 66% — turning a full-day analysis project into a 30-minute workflow.
The Challenge
A complex production line required 30-minute preventive maintenance performed by two maintenance workers once per day. The procedure had never been formally analyzed — steps were passed down by habit, with no standard sequence or separation of internal and external activities. Any improvement attempt would first require a detailed SMED study, which traditionally takes days of manual observation, stopwatch timing, and spreadsheet work.
The Solution
The Lean specialist filmed 2×30 minutes of maintenance and uploaded the videos into Power Belt's Lean Player. In another 30 minutes, every step was annotated, timed, and classified into internal and external activities. Based on this, Power Belt automatically generated the new work standard as a Gantt chart — with an optimized step sequence and clear separation of preparation from actual maintenance. The Lean specialist walked into the workshop with maintenance workers the same day, armed with a complete scenario and ready-to-implement standards.
Key Results
Preparation time dropped from 64 minutes to 21.8 minutes — a 66% reduction. Internal activities were cut from 32.1 minutes to just 7.4 minutes, a 77% improvement. The entire analysis, proposal, and standard creation was completed in a single 30-minute session using Power Belt, compared to the days it would have taken with traditional methods. The maintenance team adopted the new standard immediately, and the improvement workshop was conducted the same afternoon.
“I filmed, uploaded, and had a complete SMED proposal in 30 minutes. The workshop with maintenance started that same afternoon.”
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