Life Cycle Asset Management

Design-out maintenance is a root cause failure elimination category where the solution is to design for reliability and intentionally create highly reliable equipment through an engineering design change.

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I am a design engineer and am considering plant improvement as a more proactive activity for our department. Being in design I am interested in design-out maintenance solutions and the role they play in maintenance cost reduction. Particularly where design out solutions are used for failure elimination.

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 ACE 3T analysis is a new problem inquiry tool that lets you find simple answers to difficult problems. It does not ask you to use Lean process assessment tools or apply Six Sigma statistical analysis. You only need to use your eyes and a spread sheet to explore the details that expose the simple options to solve your problem. 

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How the 3T’s of Human Error Prevention and Mistake Proofing – Target, Tolerance, Test – were Discovered

Human errors and mistakes cause 80 percent of industrial equipment failures. That humans cause most problems has long been known. It has been difficult to find reliable ways to prevent human error, but an Arab craftsman taught me the 3Ts of error prevention and mistake proofing work.

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 Human error causes 80% of plant and equipment failures. It is the single factor, which if controlled, makes the most difference to achieving world class equipment reliability and operational success. With the introduction of low cost communication and visual devices it is now possible to assist maintenance workers proactively prevent human error. By using interactive audio-visual devices workers can be coached through a job error-free to get right-first-time quality every time.

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 Let a Plant Wellness Way EAM System-of-Reliability halve your Annual Maintenance Costs 

A Plant Wellness Way enterprise asset management system is a powerful solution for world class enterprise asset management (EAM) success. There are three scenarios when it is justifiable for a business to adopt PWW EAM as your company’s EAM methodology.

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Estimating the money for commissioning spares allowance of a capital project using the maintenance cost in the RAV ratio is probably wrong, but it is often done. The allowance also depends on the life cycle asset management processes and practices in use.

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UNLIKE LEAN AND SIX SIGMA, THE PLANT WELLNESS WAY DIFFERENCE IS IT PREVENTS OPERATING RISKS FROM STARTING WITH A SYSTEM THAT IS BUSINESS-WIDE AND GOES END-TO-END OF THE WHOLE ASSET LIFE CYCLE

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Lean and Six Sigma are point-in-time problem focused methodologies, where as PWW EAM System-of-Reliability uses the whole life cycle to build business and operational systems with processes that continually optimize productivity, minimize risk, and generate maximum operating profits.

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First parts fail, then machines stop! If its parts don’t break your machines and equipment will always be reliable

Physics-of-Failure microstructure science explains why components fail, and why they get failed during service life. Understanding Physics-of-Failure is foundational to the Plant Wellness Way EAM methodology

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Why Build a Quality Management System?

A business management system needs a quality management system built to make customers happy.

Every company already has a business management system they use to deliver products or services. If you want to be a more profitable business, you need to continually create a better management system.

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It took a long time to understand why a business in the same market did better than other businesses. Every one thought it was due to better marketing, or access to more capital. But it was not. It was simply that one business had products that better suited customer needs. The best product always gains most market share and makes the biggest profits. Which is why a business management system needs a quality management system that improves their products.

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A risk management risk matrix can trick you into leaving high consequences uncontrolled and convince you it is fine to do nothing to reduce the impacts of failure. Whether you think a bad event cannot happen has no standing in Law. The likelihood of an adverse event is unimportant; only the resultant severity is how the Law will gauge your risk abatement efforts. Did you do ‘reasonably practicable’ risk control?

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