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Home » Articles » on Maintenance Reliability

on Maintenance Reliability

A listing in reverse chronological order of these article series:



  • Usman Mustafa Syed — Aasan Asset Management series

  • Arun Gowtham — AI & Predictive Maintenance series

  • Miguel Pengel — Asset Management in the Mining Industry series

  • Bryan Christiansen — CMMS and Reliability series

  • James Reyes-Picknell — Conscious Asset series

  • Alex Williams — EAM & CMMS series

  • Nancy Regan — Everday RCM series

  • Karl Burnett — History of Maintenance Management series

  • Mike Sondalini — Life Cycle Asset Management series

  • James Kovacevic — Maintenance and Reliability series

  • Mike Sondalini — Maintenance Management series

  • Mike Sondalini — Plant Maintenance series

  • Andrew Kelleher — Process Plant Reliability Engineering series

  • George Williams and Joe Anderson — The ReliabilityXperience series

  • Doug Plucknette — RCM Blitz series

  • Robert Kalwarowsky — Rob's Reliability Project series

  • Gina Tabasso — The Intelligent Transformer Blog series

  • Tor Idhammar — The People Side of Maintenance series

  • André-Michel Ferrari — The Reliability Mindset series

by Mike Sondalini Leave a Comment

An Accuracy Controlled SOP Protects Against Human Error

An Accuracy Controlled SOP Protects Against Human Error

An Accuracy Controlled Enterprise Ace 3T Standard Operating Procedure Protects Against Human Error and Mistakes

With thousands of opportunities to make human errors and mistakes in a job an ACE 3T standard operating procedure is a powerful way to get work done right-first-time. When the situational risk from errors is too high a Plant Wellness Way EAM System-of-Reliability uses ACE 3T SOPs to ensure work tasks and activities are correct and error-free.

We’re all human, and humans make mistakes—lots of them every day. The image below warns that 10 to 30 errors per 100 opportunities is typical for trained people not using a standard operating procedure. Mistakes happen to all of us. The more complicated the job and the more stressful the situation the higher is the human error rate. A PWW EAM System-of-Reliability protects against human error by giving people an ACE 3T standard operating procedure to follow and be 100% successful.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Nancy Regan Leave a Comment

What is the REAL reason we do Reliability Centered Maintenance (RCM)?

What is the REAL reason we do Reliability Centered Maintenance (RCM)?

Why do we practice Reliability Centered Maintenance (RCM)? In this video, I share a real-life example from a recent trip that perfectly illustrates RCM’s purpose: managing the consequences of failure.

When my flight faced an issue with its auxiliary power unit (APU), the pilot used alternative methods to keep us moving safely. This experience highlights how RCM principles guide us in deciding which failures need proactive maintenance and which can be managed with other strategies. Join me, Nancy Regan, as I walk through the essence of RCM and how it helps us focus on what truly matters.

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Mike Sondalini Leave a Comment

How to Make ISO 55000 and ISO 55001 Successful 

How to Make ISO 55000 and ISO 55001 Successful 

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…]

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

by James Reyes-Picknell Leave a Comment

What are You Missing?

What are You Missing?

Many maintainers fail to make improvements or make them stick. It’s not lack of intention, it’s a chaotic environment and inability to really lead change effectively.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Joe Anderson Leave a Comment

Failure Management in Maintenance: Turning Setbacks into Success

Failure Management in Maintenance: Turning Setbacks into Success

Failure is an inevitable part of maintenance operations. Machines break down, components wear out, and unexpected issues arise despite the best preventive measures. However, the difference between a high-performing maintenance team and one that struggles lies in how failures are managed. Effective failure management is not about eliminating all failures—an impossible goal—but about controlling their impact, learning from them, and using them as opportunities to improve reliability and efficiency.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Nancy Regan Leave a Comment

Is Failure Data Essential for RCM? Insights from Resnikoff’s Conundrum

Is Failure Data Essential for RCM? Insights from Resnikoff’s Conundrum

Do we need comprehensive failure data to perform Reliability Centered Maintenance (RCM)? This question brings us to Resnikoff’s conundrum, a thought-provoking concept introduced by mathematician Resnikoff in the 1970s. Resnikoff pointed out that while failure data is useful, data on critical failures—which we aim to prevent—is often missing or minimal. So, how do we manage RCM effectively without it?

In this video, I explain how a facilitated working group approach to RCM fills in these data gaps by leveraging the knowledge and experience of equipment experts. Join me, Nancy Regan, as we explore this unique aspect of RCM!

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Kerina Epperly Leave a Comment

Unlocking Plastic Deformation

Unlocking Plastic Deformation

Failure Fingerprint: Plastic Deformation in Bearings

(Also known as “Brinelling,” “False Brinelling,” or “Plastic Flow” depending on cause and appearance)


Abstract: Unlike fatigue cracks or abrasive wear, plastic deformation represents a threshold failure where the material’s yield strength is exceeded, leading to permanent dimensional change. In high-precision components like bearings, even microscopic plastic flow the “failure fingerprint” can trigger catastrophic system vibration or total seizure. This article explores identifying markers of Brinelling, torsional yielding, and metallurgical slip.


[Read more…]

Filed Under: Articles, on Maintenance Reliability, The Reliability Crime Lab

by Mike Sondalini Leave a Comment

Developing a Planned Maintenance Strategy based on Criticality

Developing a Planned Maintenance Strategy based on Criticality

Use Equipment Criticality to Match Planned Maintenance Strategy to the Operational Risks

Planned maintenance has the purpose of rejuvenating equipment before parts start failing. Use maintenance strategy based on continual renewal to reduce operating equipment risk of failure so that you have your plant and equipment in good condition and thus free of age and stress related defects waiting for the chance to fail.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Nancy Regan Leave a Comment

Are You Writing Failure Modes All Wrong? Learn the Truth

Are You Writing Failure Modes All Wrong? Learn the Truth

In this video, we’re testing our knowledge of how to write Failure Modes correctly — a crucial step in the Reliability Centered Maintenance (RCM) process. As my mentor John Moubray taught, we manage physical assets at the Failure Mode level, so it’s essential to get them right. I’ll walk you through a few examples to show what separates a properly written Failure Mode from a Failure Effect.

Learn how to identify specific Failure Modes that will help you get on the “right road” to creating safe and effective proactive maintenance tasks, intervals, and Default Strategies. Let’s dive in and see how well we know Failure Modes!

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Kerina Epperly Leave a Comment

Decoding Early Thermal Stress in Rotating Equipment

Decoding Early Thermal Stress in Rotating Equipment

Visual Inspections That Reveal Early Thermal Stress Damage

Thermal stress in components leads to premature failure. In the high-stakes world of industrial maintenance, the most dangerous failures are those that develop in silence. Thermally induced shaft damage typically does not announce itself with a sudden snap; rather, it matures through a progression of temperature gradients, mechanical constraints, and repeated thermal cycling. By the time cracks or permanent deformation become visible to the untrained eye, the window for low-cost intervention has usually closed.

Visual inspection and thermal imaging are both excellent non-destructive testing (NDT) techniques that detect impending failures early. In this article, we will discuss what to look for, what it means, and potential counter measures.


“Training site personnel to look for early indicators of thermal stress damage on shafts, couplings, and bearings is the single most effective way to prevent premature breakdown.”


[Read more…]

Filed Under: Articles, on Maintenance Reliability, The Reliability Crime Lab

by André-Michel Ferrari Leave a Comment

Multipopulation or Mixed Weibulls Overview

Multipopulation or Mixed Weibulls Overview

The Weibull distribution is a highly popular workhorse in Reliability Engineering. Sometimes a little too popular.  Its shape parameter (β) provides valuable information on the life characteristics of assets. In practice, a single Weibull distribution often fails to represent field or fleet data because the observed failures are not generated by only one homogeneous population. Instead, the data is frequently a blend of multiple underlying subpopulations. Relating to different designs, suppliers, duty cycles, environments, maintenance histories, etc. This is where multipopulation (mixture) Weibull models become valuable. They explicitly model heterogeneity rather than forcing one curve to “average out” incompatible behaviors. It is therefore incorrect to assume the population of failure times comes from a single Weibull distribution characterized by shape parameter 𝛽 and scale parameter 𝜂.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, The Reliability Mindset

by Mike Sondalini Leave a Comment

TRUE COST OF MAINTENANCE

TRUE COST OF MAINTENANCE

The true cost of maintenance to a company includes the lost production time, cost of utilities not used, overhead costs, handover costs and more.

A 6-step procedure that guides you and your organization, department, and team to analyze your business and operational risks, and develop an enterprise asset management system that is purpose-built to deliver your organization world class reliability.

[Read more…]

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

by James Reyes-Picknell Leave a Comment

Back to Basics? Really?

Back to Basics? Really?

Some managers resist outside help to make improvement in how they are managing reliability and maintenance. They think they can “get back to basics” first and then re-assess. They fail to see that if they could really do that on their own, they wouldn’t have allowed the slide to where they are today.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Nancy Regan Leave a Comment

3 Ways to Do RCM — And the Best Method Revealed!

3 Ways to Do RCM — And the Best Method Revealed!

In this video, we’re exploring the best way to conduct a Reliability Centered Maintenance (RCM) analysis. When it comes to RCM, there’s definitely a “recipe” for success that includes two key ingredients: firsthand knowledge of the equipment and its operating environment, and a strong understanding of RCM principles and how to apply them.

We’ll break down three common approaches to RCM—outsourcing, single analyst, and the facilitated working group approach. Discover why the facilitated working group approach stands out as the best way to ensure a comprehensive, effective RCM analysis. I’m Nancy Regan, and I hope you enjoy the video!

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Joe Anderson Leave a Comment

The Role of MRO and Stores in Our Framework

The Role of MRO and Stores in Our Framework

Maintenance, Repair, and Operations (MRO) and the management of spare parts inventory (stores) are often overlooked elements in a framework. However, they play a critical role in ensuring that maintenance teams have the right tools, parts, and materials needed to keep assets running efficiently. Without a well-structured MRO and stores strategy, even the most proactive maintenance programs can suffer from delays, unplanned downtime, and excessive costs.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

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