Facilities managers often grapple with a wide range of responsibilities, from urgent repairs to routine upkeep, leaving little room for inefficiencies.

Lean maintenance offers practical solutions by helping teams streamline operations, eliminate waste, and make smarter use of their time and resources.

With more than two decades of experience across warehousing, plant management, and consulting, presenter Andy Gager emphasizes a clear message: inefficiency in maintenance is costing facilities far more than they realize and it's time to fix the system, not just the equipment.

Gager is the CEO of AMG International Consulting and long-time columnist for Facility Maintenance Decisions magazine.

In this webcast, Gager outlines how typical maintenance departments suffer from poor craft utilization, with nearly 50 percent of a technician's time lost to searching for tools or walking to job sites. In addition, 63 percent of maintenance activities are self-induced, and 74 percent of equipment failures stem from improper operation. Coupled with bloated inventories where more than half of parts haven’t been used in three years, it's clear that many facilities are bleeding resources.

So what's the solution? A return to basics through lean maintenance principles, including 5S, Kaizen (small continuous improvements), and reliability-centered maintenance. Gager stresses the importance of mapping out work processes, defining clear roles and responsibilities with tools like RACI charts, and standardizing task execution to ensure consistency, whether a technician has been on the job for 20 years or 20 minutes.

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