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…]

by James Reyes-Picknell Leave a Comment

Is there going to be a 4th edition of “Uptime”?

I’ve been asked this many times, along with, “when will it be available in “my language?”

Here’s the answer… My book Uptime – Strategies for Excellence in Maintenance Management is now in its 3rd edition, and it includes a chapter on Evidence-Based Asset Management. That approach—using data plus expert knowledge—was groundbreaking back in 2015. Since then, AI, machine learning, and advanced analytics have changed the game. The science behind Uptime is still valid, but the methods need updating.

So, people ask me all the time: “Is there a 4th edition coming?” My answer: “Yes… but not in the way you might expect.”

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by Nancy Regan Leave a Comment

Is RCM the Secret to Reducing Maintenance?

Can Reliability Centered Maintenance (RCM) reduce proactive maintenance? The answer is: It depends.

In this video, I share real-world examples of organizations that reduced proactive maintenance by over 50% after implementing RCM. But there’s more to the story—what if your organization is reactive and struggling with downtime? In that case, RCM might actually increase proactive maintenance to improve reliability and reduce chronic issues.

The key is to focus on identifying proactive maintenance tasks that are technically appropriate and worth doing. RCM helps ensure your equipment serves you reliably, whether that means reducing or increasing proactive maintenance.

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by Joe Anderson Leave a Comment

The Importance of an Asset Management Policy in Overall Asset Management

Asset management is a critical function in any organization that relies on physical assets to deliver products or services. Whether in manufacturing, utilities, transportation, or facilities management, the ability to maximize asset performance while minimizing costs and risks is key to long-term success. However, effective asset management doesn’t happen by chance—it requires a structured approach. This is where an Asset Management Policy becomes essential.

An Asset Management Policy serves as the foundation for an organization’s asset management strategy. It defines the principles, objectives, and guidelines that govern how assets are acquired, maintained, and retired. Without a clear policy, asset management can become inconsistent, reactive, and inefficient.

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by Mike Sondalini Leave a Comment

The Happiness and Pleasure of Doing World-Class Work Quality

As The Saying Goes, “How You Do Anything Is How You Do Everything.”

Your work quality should bring you great joy every time you do your job. There’s a little secret that will let you love work and draw happiness from every task you do.

Competition against others only gives you satisfaction when they lose, and you beat them. It’s such a sad, poor way to live life. Yet competition against yourself brings you joy every time you use it.

I love making my bed to world-class work quality in the morning. It makes me happy. That’s because the job satisfaction is entirely in my control. Whether you leave your bed looking like a tornado hit it, or you leave it like a 5-star showroom display, is completely up to you and you alone. I leave my bed made up to 5-star world-class work quality every day because it makes me proud. And being proud of my work brings me satisfaction and happiness.

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by Nancy Regan Leave a Comment

Do You Need RCM, FMEA, FMECA, or CBM? The Answer May Surprise You!

Should you use Reliability Centered Maintenance (RCM), Failure Modes and Effects Analysis (FMEA), Failure Modes Effects and Criticality Analysis (FMECA), or Condition Based Maintenance (CBM)?

In this video, I explain how RCM incorporates all of these processes into one comprehensive approach. By following the RCM process — steps like identifying Functions, Failure Modes, Failure Effects, and assessing Consequences — you naturally create an FMEA, a FMECA, and consider CBM as a potential failure management strategy.

With RCM, you don’t have to choose — you do it all! Watch to learn how this powerful methodology ensures you get exactly what you need from your equipment.

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by James Reyes-Picknell Leave a Comment

Data Driven, or Data Enabled?

We hear about data driven decisions and it’s become somewhat of a mantra for IT departments, managers and even executives. But they’ve got it wrong! Data shouldn’t drive anything – it can’t. But it can be a powerful enabler if we want. A subtle shift in language can lead to big gains in performance!

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by Mike Sondalini Leave a Comment

Total Cost of Downtime

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.

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by Nancy Regan Leave a Comment

Failure Effects in RCM: Why They Matter and How to Write Them

In this video, filmed at the historic La Popa Monastery in Cartagena, Colombia, I dive into the importance of Failure Effects in the Reliability Centered Maintenance (RCM) process. Failure Effects might seem like just one step in the RCM journey, but they’re essential for understanding the impact of Failure Modes — and that’s what makes them so special.

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by Joe Anderson Leave a Comment

CMMS in Maintenance

The Importance of CMMS in Maintenance: A Game Changer for Reliability and Efficiency

In today’s fast-paced industrial and manufacturing environments, maintenance teams are under constant pressure to keep assets running efficiently while minimizing downtime and controlling costs. A Computerized Maintenance Management System (CMMS) has become an essential tool for achieving these goals. More than just a digital record-keeping system, a CMMS provides a structured and data-driven approach to asset management, work order tracking, preventive maintenance scheduling, and overall maintenance optimization.

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by Mike Sondalini Leave a Comment

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.

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by Nancy Regan Leave a Comment

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.

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by Mike Sondalini Leave a Comment

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.

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by James Reyes-Picknell Leave a Comment

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.

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by Joe Anderson Leave a Comment

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.

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