Shutdown maintenance is a critical process in various industries due to process downtime losses. Lean Six Sigma (LSS) in shutdown maintenance is a systematic approach for continuous improvement to achieve shutdown objectives and reduce downtime. Through a systematic review of relevant literature, case studies, and published materials, this study investigates the potential of LSS principles to improve project management performance. An integrated LSS DMAIC framework was developed to improve the shutdown maintenance efficiency. Furthermore, a case study conducted for maintenance shutdown project in one of the petrochemical companies in Egypt. Results indicate that the proposed methodology is successful in improving shutdown project KPIs. For example, planned maintenance improved from 86% to 93%, operational reliability improved from 72% to 79%, and shutdown project efficiency improved from 62.3% to 69.7 %.

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A. H. Gomaa “Improving Shutdown Maintenance Management Performance Using Lean Six Sigma Approach: A Case Study” International Journal of Applied and Physical Sciences, vol. 10, pp. 1-14, 2024. Doi: https://dx.doi.org/10.20469/ijaps.10.50001