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Home » Archives for Mike Sondalini » Page 11

Mike Sondalini — Thought Leader

Author of Plant Maintenance, Maintenance Management, and Life Cycle Asset Management.


This author's archive lists contributions of articles and episodes.

by Mike Sondalini Leave a Comment

How Industrial Operations use Plant Wellness Way to get World-class Production

How Industrial Operations use Plant Wellness Way to get World-class Production

An Executive Report for CEO’s, Executives, and Senior managers in industry and manufacturing.

Utmost operating profits, lowest maintenance costs, world class reliability, & outstandingly effective physical asset management the Plant Wellness Way

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

In the Plant Wellness Way (PWW) you do nothing to your business until you have total confidence that what you do, and how it will be done, will be extraordinarily successful.

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

When To Use Stainless And Alloy Steel In Place Of Plastic Or Carbon Steel Items

When To Use Stainless And Alloy Steel In Place Of Plastic Or Carbon Steel Items

When To Use Stainless And Alloy Steel In Place Of Plastic Or Carbon Steel. There are many times when it is false economy to use carbon steel and plastic items. It is often better to use stainless and alloy steels instead. They last longer and deliver a lower life cycle cost.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

Human Factors in Human Error Prevention

Human Factors in Human Error Prevention

Understanding and Using Human Factors for Human Error Prevention and Mistake Proofing Gets You a Great Safety Advantage

There are many businesses around, even national and international sized companies, who have done an OHS risk assessment for their operations and still have poor workplace safety performance and lousy safety statistics. Clearly they got something seriously wrong when they undertook their operational health and safety (OHS) risk assessment process.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Rate of Occurrence of Failure

Rate of Occurrence of Failure

The Rate of Occurrence of Failure (ROCOF) curve is the sum of all the individual component failure curves across the service life of an asset. As shown below, it looks like a bathtub, giving it the nickname, a bathtub curve.

Equipment reliability is malleable by choice of policy and quality of practice.

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Surprising Insights from Simple Run Charts

Surprising Insights from Simple Run Charts

The late quality guru W. Edwards Deming advised graphing the process variables and the process outputs across time on a run chart (a time-series plot) to identify uncertainty and variability. When the run charts are used together, they help to identify the times and causes of poor results.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Is it Time to Kill Your Organization to Build a Better One?

Is it Time to Kill Your Organization to Build a Better One?

Every organization and organism’s performance is limited to the capability of its design. If you want better business results, then get or build a new organization with systems designed to naturally deliver the outcomes and profits you want. Nothing else you do will ever work as well!

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini 1 Comment

Two Ways to Get High System Reliability

Two Ways to Get High System Reliability

There are only two ways to get high system reliability if you want a highly reliable system. Equipment in an operation can be configured in series or in parallel. In series, one item connects sequentially to the other. In parallel, each item is arranged as a companion, where one duplicates the other.

A series arrangement needs exceptionally reliable individual equipment to get a highly reliable system. A parallel arrangement can form a highly reliable system even if individual equipment has poor reliability.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

Maintenance Backlog Work Order Scheduling using Queuing Theory

Maintenance Backlog Work Order Scheduling using Queuing Theory

Your maintenance backlog is a queue of work orders. You can manage maintenance backlogs more effectively by applying queuing theory.

When maintenance work order time estimates are close to actual times, queuing theory can be applied to schedule the most effective arrangement of your maintenance backlog.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Create Your Organization’s ISO 55001 SAMP

Create Your Organization’s ISO 55001 SAMP

PLANT WELLNESS WAY EAM METHODOLOGY USES THE ‘IONICS’ STRATEGIC ASSET MANAGEMENT PLAN FOR BUILDING AN ASSET MANAGEMENT SYSTEM

SIMPLY FOLLOW THE INDUSTRIAL AND MANUFACTURING WELLNESS BOOK TO CREATE YOUR ORGANIZATION’S ISO 55001 SAMP

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

The Differences between Proactive Maintenance Strategy and Plant Wellness Reliability Strategy

The Differences between Proactive Maintenance Strategy and Plant Wellness Reliability Strategy

Many people believe Proactive Maintenance is the ultimate physical asset management strategy—but there is one better strategy. To get world class reliability at the least cost there must be no maintenance. Only a “wellness” paradigm can achieve that result.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Pumping Abrasives With Progressive Cavity, Helical Rotor, Eccentric Screw Pumps

Pumping Abrasives With Progressive Cavity, Helical Rotor, Eccentric Screw Pumps

Often used to pump slurries, helical rotor pumps (also known as progressivity cavity pump, eccentric screw pump, mono pump) use a spiral rotor to move a chamber full of product through the pump. When moving slurries it is critical that the rotor wipes the rubber or elastomer stator firmly, else fine particles get between the rotor and stator and rip material out. This article discusses a major operating problem when the wrong size rotor was used in a stator.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

Doing Equipment Criticality is as Simple as ABC

Doing Equipment Criticality is as Simple as ABC

This activity-based costing (ABC) method calculates the actual cost of a failure incident and uses the total dollar value to the business as the means to rate equipment criticality. The criticality of an item of plant is determined by the cost consequences and losses of equipment failure across the whole company. Using this method puts a real dollar value on a production equipment loss incident. This financially robust and reliable method provides an accurate way to prioritise production equipment and to justify the necessary risk management and maintenance measures to protect against failure. It recognises that a production failure event has cost repercussions throughout an organisation affecting many people and departments, with all of them incurring costs. These costs are lost business profit that could have been earned and banked, but for the incident. The financial model reflects the actual production and maintenance practices in the operation and their cost implications to the whole organisation if they are inadequate. It delivers clear indication of the responsibility’s managers, supervisors, operators, and maintainers have of properly running, maintaining, and caring for plant and equipment to prevent production-losses to the business.

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Lean Improvement Success at a Concrete Reinforcing Bar Manufacturer

Lean Improvement Success at a Concrete Reinforcing Bar Manufacturer

Reinforcing bar is forged steel used in concrete to give the otherwise weak concrete structural tension strength. Reinforcing bar manufacturing is done in a factory using computerised machines to straighten, cut and bend the steel. It is a highly automated process once the bar is loaded onto the manufacturing machinery. These machines are computer controlled and form the bar to the shape and dimensions instructed. The bar specification and dimensions are identified from the engineering drawings by the Scheduler who enters the details into a scheduling software program. The program converts the reo-bar size requirements into computer controlled manufacturing instructions for the machines and a delivery schedule for the production shop.

Our assignment was to identify opportunities to improve the business and streamline the operation from production through to delivery.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Introducing Industrial and Manufacturing Wellness

Introducing Industrial and Manufacturing Wellness

Plant Wellness Way EAM methodology uses systems engineering and life-cycle risk elimination to re-engineer your company and operational processes to get utmost asset reliability and maximum success and profits from your operating plant and equipment

You get optimal life-cycle asset management, production, and business processes delivering outstanding plant, equipment, and process reliability

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Example Accuracy Controlled Enterprise (ACE) 3T Job Procedure

Example Accuracy Controlled Enterprise (ACE) 3T Job Procedure

Example ACE 3T (Target-Tolerance-Test) Procedure with Reliability Standards: Machine performance is totally dependent on human beings. To address the problem of human error causing equipment failure, an Accuracy Controlled Enterprise sets best practice quality standards and uses 3T Target-Tolerance-Test work task quality control that assures high quality workmanship for high reliability results. Their work procedures are standardised so everyone follows the same methods to produce the same results, their training teaches people how to do craftsmanship work that creates outstandingly reliable plant and machinery. They create the reliability they want and as a result achieve operational excellence.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

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