Enhancing shutdown maintenance performance using Lean Six Sigma: a case study

Purpose Effective shutdown maintenance of critical equipment is essential for ensuring smooth operations, improving safety, enhancing reliability and minimizing production and financial losses during downtime. This study aims to propose a Lean Six Sigma (LSS) framework to optimize shutdown maintenance management for critical equipment. Design/methodology/approach This research develops and implements a step-by-step LSS framework to enhance shutdown maintenance performance. The study follows the LSS-DMAIC methodology and uses a case study approach to illustrate its practical application. Findings Data analysis at various stages identified root causes of failure and waste. In a case study focused on the shutdown maintenance of a feed water pumping station in a steam system at a petrochemical company in Egypt, non-value-added time was reduced by 60%, downtime was decreased by 43% and shutdown efficiency improved from 27% to 49%. Research limitations/implications This case study was conducted at a single industrial site with a specific service system. Expanding the research to multiple case studies would help generalize the findings. Nonetheless, this study offers valuable insights for further research and broader application. Practical implications The findings provide a useful framework for managers and engineers aiming to enhance maintenance efficiency, improve the reliability of production processes and optimize shutdown maintenance practices. The procedures developed can guide future maintenance system management. Social implications Improving people culture and quality. Originality/value This study is one of the few that applied LSS to the shutdown maintenance of critical equipment in industrial settings. It demonstrates how LSS tools can drive significant improvements in maintenance efficiency and contribute to continuous improvement efforts.