Mike Sondalini — Thought Leader

Develop an Enterprise Asset Risk Control Strategy for Enterprise Resource Wellness

 The 6-Step ‘Plant Wellness Way EAM System-of-Reliability’ methodology is more that DMAIC and more than using ISO 55001. It does not seek acceptable failure rates; its objective is total failure elimination from your operation. 

In this strategy, your enterprise would be viewed through lenses of increasing magnification. The view at the highest level is the overall value stream map. Each high-level map comprises your company’s key activities, so the second level view is each individual activity. Each activity comprises many resources (tools, instruments, equipment, operators, materials, work products, etc.) so the third level view is each individual resource. Finally, each resource comprises many components, so the fourth level view is for each component. An appropriate risk abatement analytical procedure would be applied to a specific level with the requirement that a given procedure must be capable of producing a zero-failure rate. Such enterprise risk control procedures would include Process Optimization, an ACE 3T Quality Management System, and equipment reliability analysis.

[Read more…]

Series system and parallel system properties provide valuable business and operational implications.

Reliability Properties Of Series Systems

There are three reliability properties of equipment and parts in a series system arrangement. These properties impact on business and operational decisions and performance.

1.     The reliability of a series system can be no higher than the least reliable component.
2.    If more items are added into a series system, then the reliability of other items must increase if the original system reliability is to be maintained.
3.    A small rise in reliability of all items causes a much larger rise in the total system reliability.

[Read more…]

OPERATIONAL EXCELLENCE REQUIRES BEST-PRACTICE PHYSICAL ASSET MANAGEMENT, MAINTENANCE MANAGEMENT, AND WORLD CLASS RELIABLE EQUIPMENT, WHICH YOU GET WITH A PLANT WELLNESS WAY EAM SYSTEM-OF-RELIABILITY

Successful Operational Excellence requires a business-wide, life-cycle asset management system with the methods and practices that ensure utmost productivity and top-of-class operational performance

[Read more…]

There are only two ways to get high system reliability: meeting outstanding task quality performance standards so excellence is done everywhere, and by building parallel arrangements where the failure of one has no impact on system performance. Both are done in a PWW EAM System-of-Reliability

Equipment can be configured in series or in parallel arrangements. A series arrangement is when one item or task connects sequentially to the next. It takes only one item to fail in a series arrangement and the whole system will fail. Exceptionally reliable individual equipment is needed to experience a high-reliability system with a series arrangement.

Parallel arrangements are when each item is arranged as a companion, one duplicates another. In this circumstance, exceptionally reliable systems can be formed even if individual equipment has poor reliability.

A system is formed when equipment is combined to do a duty. For example, when a pump, coupling, and electric motor are connected they form a series system used to move liquid through pipes from one point to another.

[Read more…]

AN ENTERPRISE ASSET MANAGEMENT SYSTEM UNITES OPERATIONS, ENGINEERING, MAINTENANCE, AND THE SUPPLY CHAIN ACROSS THE ASSET LIFE CYCLE TO MEET CORPORATE BUSINESS OBJECTIVES AND PRODUCE HIGH PLANT AVAILABILITY AT THE LOWEST LIFETIME COST AND MOST OPERATING PROFIT

—

An enterprise asset management system needs asset reliability improvement processes throughout the life cycle that ensure utmost reliability and eliminate the need for maintenance. You can do that with a Plant Wellness Way EAM System-of-Reliability

What exactly is an Enterprise Asset Management System?

[Read more…]

Reliability Block Diagrams are a powerful reliability analysis tool. They are visual representation of reliability and risk that exists within machinery or work processes.

They allow the user to notate the reliability of each part or task and calculate the reliability for the whole scenario. The use of Reliability Block Diagrams extends to all aspects of operational processes and procedures, both as series and parallel arrangements.

Once a Reliability Block Diagram is created, you can do “what-if” scenarios to identify the defects that can happen to each part. This information allows you to then make informed decisions about to how to proactively eliminate the causes of each risk or defect, and by extension, eliminate that cause of failure.

[Read more…]

From Plant Wellness Way Eam System-Of-Reliability

VITAL PLANT AND EQUIPMENT RELIABILITY TIPS FOR WORLD CLASS PRODUCTION RESULTS WITH A PWW EAM SYSTEM-OF-RELIABILITY

—

With Plant Wellness Way EAM you will change to engineering, operating, and maintenance methods that guarantee world class reliability practices are done throughout your company and its operations

Imagine your business without breakdowns, fewer spare parts in a smaller parts Store and lower operating costs everyday. All the while you enjoy world class reliability success that delivers outstanding plant availability in all of your operating plants. To get to this world you will need to Change the Game to one where you guarantee fantastic reliability success! [Read more…]

The total cost of downtime extends across the business. In the worst cases, it impacts the entire organisation and customers.

From the moment of failure to the restart of production, no saleable product is made. Instead, money is spent on repairs, with continued fixed costs, and any potential profits that could have been made from saleable products is lost. The graph below illustrates what happens to production time and costs when operations stop due to equipment breakdown (t1). The time and costs required to repair the equipment to operational levels (t2) is unknown at the start of the breakdown.

During this time (t1 to t2) resources and money are needed to return the equipment to operation. Additional costs due to loss of production and therefore potential profit losses are also incurred in this time.

[Read more…]

ISO 55000 and ISO 55001 are frameworks into which you must add the correct policies, procedures, knowledge, and actions that deliver world class physical asset management. They cannot of themselves cause asset management, maintenance and operational excellence. Users of ISO 55000 and ISO 55001 must turn the framework into a full set of the correct and proper processes and practices used business-wide and life-cycle-long in your company to cause it to operate at world class performance. 

What is missing in ISO 55001 you do with the Plant Wellness Way enterprise asset management methodology. There is but one rule to follow in the PWW EAM methodology to get the best asset management and operational excellence solution: Produce the least atomic stress state in component materials-of-construction all the time. Select strategies, procedures and practices that cause that result and you have the best asset management solution to feed into an ISO 55001 framework. Plant Wellness Way EAM perfectly complements ISO 55000 and ISO 55001 so that when used together you build a life cycle EAM system with the processes and practices that ensure outstanding equipment reliability and great enterprise asset management success.

[Read more…]