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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

Equipment Maintenance Strategy 101: Match Strategy to Equipment Risk

Equipment Maintenance Strategy 101: Match Strategy to Equipment Risk

Maintenance Strategy 101: Correct Equipment Maintenance Management Strategy Selection makes All the Difference

You select and apply maintenance strategy with the purpose of controlling failure. Your maintenance management starts on the project drawing board. If you only select your maintenance management strategies when the equipment is installed, you will always be fighting a losing battle!

Maintenance is a risk management practice used to maximise production and minimise loss and waste.  Selecting a successful maintenance strategy requires a good knowledge of equipment failure behaviour and maintenance management practices.  Once you appreciate why equipment fails, how equipment fails and when equipment fails you can select the right mix of maintenance strategies to extend and maximise its service and performance.This article takes you through the factors which affect equipment performance and service life.  It also introduces you to the maintenance strategies available to you today and how they work.  You will also discover within the article many maintenance management benefits that each maintenance strategy will bring you.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Nancy Regan Leave a Comment

Which Is Part of RCM? CBM, FMEA, or Both?

Which Is Part of RCM? CBM, FMEA, or Both?

Test your knowledge of Reliability Centered Maintenance (RCM) with this quick quiz! Which of the following are part of the RCM process? Is it:

A) CBM

B) FMEA

C) CBM and FMEA

D) None of the above

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Miguel Pengel Leave a Comment

Demystifying the ISO55001 Certification Process

Demystifying the ISO55001 Certification Process

Many years back when I started my Asset Management journey, the ISO55000 series of standards was always lingering overhead as the “bible” of asset management. The problem was that the systems and processes we tend to learn in this field stem from those standards, but rarely do we deep dive into the documentation and try to mind map for ourselves how it all fits together. [Read more…]

Filed Under: Articles, Asset Management in the Mining Industry, on Maintenance Reliability

by Mike Sondalini 1 Comment

Developing Enterprise Asset Management, Maintenance and Reliability KPIs

Developing Enterprise Asset Management, Maintenance and Reliability KPIs

Developing Maintenance KPIs, Reliability KPIs, And Enterprise Asset Management KPIs Of Value For Good Decision Making

When developing maintenance KPIs, or any performance measure, you will have no real ‘grass-roots’ support, nor lasting success, until people are involved in setting their own measures and key performance indicators.

—

I’ve been tasked with developing maintenance KPIs and equipment reliability KPIs.

I would be thankful if you guide me to a proven list of maintenance and reliability KPI’s. We would like to measure performance on individual plant and corporate levels.

We have 120 plants for various products: metals, chemicals, petrochemicals, fertilizers.

We are not currently using unified measures, i.e. every plant is going in its own direction, and we now are looking to unify maintenance and reliability across the corporation by introducing a reliability solution to create a scientific maintenance strategy. Part of our strategy is to introduce specific KPIs which have to be achieved by all plants.

[Read more…]

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

by James Reyes-Picknell Leave a Comment

Is Perfection Getting in Your Way?

Is Perfection Getting in Your Way?

Perfection is difficult to achieve. It takes a lot of work and that delays progress. In operational environments that can lead to lost or deferred opportunities, and leave money on the table.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Nancy Regan Leave a Comment

When to apply Reliability Centered Maintenance (RCM)

When to apply Reliability Centered Maintenance (RCM)

The Surprising Answer!

True or False? Can RCM Be Applied at Any Stage in an Asset’s Lifecycle.

In this video, I tackle a common question: Can Reliability Centered Maintenance (RCM) be applied at any point in an asset’s lifecycle? The answer is True! While it’s best to start RCM as early as possible—ideally at the design stage—many successful RCM programs around the world have been implemented long after systems were fielded.

Because RCM is a zero-based process, applying it to legacy equipment offers a chance to reevaluate years of tradition and habits, ensuring that the most safe and cost-effective Failure Management Strategies are in place. RCM’s flexibility means it can deliver great results at any point in an asset’s lifecycle.

I’m Nancy Regan, and I hope you enjoy this quick dive into the versatility of RCM. Thank you for watching!

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Joe Anderson Leave a Comment

Defect Elimination: The Cornerstone of Equipment Reliability

Defect Elimination: The Cornerstone of Equipment Reliability

In the pursuit of operational excellence and equipment reliability, defect elimination stands as a powerful and proactive strategy. It focuses on identifying and addressing the root causes of failures and inefficiencies, rather than repeatedly treating the symptoms. By targeting the sources of defects, organizations can significantly reduce downtime, extend asset lifespans, and improve overall productivity. 

What is Defect Elimination? 

Defect elimination is the systematic process of identifying, analyzing, and removing defects that lead to equipment failure or suboptimal performance.These defects can take many forms, including design flaws, operational errors, poor maintenance practices, or even environmental conditions. The goal is to ensure that equipment operates as intended, reliably and efficiently, with minimal intervention.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Kerina Epperly Leave a Comment

The Curious Case of “Normal” Bearing Failure

The Curious Case of “Normal” Bearing Failure

When Poor Habits Become the Norm

Opening Scene

Imagine an intricate and lengthy production line, where every minute of inactivity costs thousands of dollars. The constant buzz of motors and conveyors conceals a profound tension: production goals are approaching, supervisors are vigilant, and the pressure remains unyielding. 

In a constrained environment with a limited maintenance budget and sparse spare parts, your inexperienced and stretched-thin team constantly reacts to urgent breakdowns, prioritizing speed over thoroughness. Shortcuts become necessary for survival, leading to misaligned work and temporary fixes. While immediate repairs may succeed, small defects accumulate, resulting in entrenched bad habits and hidden failures. Eventually, a critical breakdown occurs, revealing the underlying issues, marking the start of a necessary investigation. [Read more…]

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

by Mike Sondalini Leave a Comment

Equipment Reliability 101

Equipment Reliability 101

Learn Vital Equipment Reliability Basics for Equipment Reliability Management Success

Learning how to run your industrial plant and equipment to get outstanding reliability requires an understanding of its failure mechanisms.

You can have tremendous equipment reliability if you use the right maintenance strategies at the right times during the equipment life cycle to prevent the causes of failure.

Abstract:

Equipment Reliability Basics 101 for Reliability Management. When you understand the behaviour of equipment over its lifetime you will understand why proactive maintenance (as opposed to repairs) is critical. Our technologically based society depends on machinery and equipment to keep it operating. Knowing how equipment behaves during its operating life, and why it fails from time to time, means you can set up the right maintenance strategies to deliver lifetime reliability. Learn to apply the correct ways to use equipment failure curves to select your maintenance strategies. Change your maintenance and operating practices to control and eliminate failure and ensure you deliver outstanding equipment reliability.Keyword:  Keywords: Equipment reliability management, reliability curves, equipment failure curves

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Nancy Regan Leave a Comment

The Best Definition of Reliability Centered Maintenance I Ever Heard

The Best Definition of Reliability Centered Maintenance I Ever Heard

Storytime: What is Reliability Centered Maintenance (RCM)? This is the best definition of RCM I ever heard.

In this video, I share a story that has stuck with me throughout my 26-year journey with Reliability Centered Maintenance (RCM). It all started when I was working as a civilian employee at the US Navy’s Naval Warfare Center in Lakehurst, New Jersey. One evening, during a dinner with the British Royal Navy’s RCM team in Bath, England, Commander Andrew Matters shared a simple yet profound definition of RCM: “RCM is nothing more than common sense applied to physical assets.” That definition has guided my understanding of RCM ever since.

RCM might seem complex, but at its core, it’s grounded in practical, common-sense principles. In this video, I explain how RCM helps us identify safe and cost-effective maintenance tasks, manage failure modes, and build a strong reliability culture. When applied correctly, RCM has the power to transform organizations—and I’ve seen it happen firsthand.

What’s keeping you from carrying out a couple of RCM pilot projects? Why not see for yourself how RCM can make a difference for your equipment and your reliability team?

I’m Nancy Regan. Thank you for watching!

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by André-Michel Ferrari 2 Comments

Relia-nomics – When Reliability meets Economics

Relia-nomics – When Reliability meets Economics

In an increasingly complex and interconnected world, ensuring that systems—from machinery to software, from power networks to consumer products—perform reliably across their intended lifetimes, is essential not only for safety and quality but also for economic viability. This intersection between ensuring dependable performance and managing costs is broadly studied under what is known as Reliability Engineering and Economics. Or Relia-nomics.

[Read more…]

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

by Mike Sondalini Leave a Comment

Business Risk Hierarchy

Business Risk Hierarchy

There is a direct connection between the microstructure health of your equipment parts and your operational and business success

There are key concepts and practices that an organization needs to use if they want optimal asset health from their plant and equipment. The greatest successes come when operating and safety risks are eliminated at their root causes. The Plant Wellness Way EAM methodology focuses on getting lasting asset health so world class operating performance is normal in your company day-after-day. Its processes and analysis tools create a system-of-reliability that gets exceptional asset health and delivers the greatest ROI from each operating asset throughout its service life.

Risk is the total losses suffered when any asset’s components may fail. The causes of failure are the environmental and operating stresses that affect a component’s microstructure. This means that world class reliability is the effective, complete remove of the causes of failure, also known as risks, from your operations. [Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by James Reyes-Picknell Leave a Comment

Is Your Project Ready for Operations?

Is Your Project Ready for Operations?

Is your project ready for operations when you want to start up? Can you commission and start up with ease and expect to reach full and steady production quickly? Or is your experience with project start ups more chaotic?

Chaos is natural

Conceptually, entropy is a scientific measure that represents that natural state of everything – chaos. The more chaotic things are, the more entropy they have. We tend to prefer things orderly and predictable. To achieve that we add energy, but without it, we will have chaos. If start ups after a capital project are chaotic, it means you have missed something. Think of it as not having enough energy. That energy is fore-thought and preparation. With it, your project is ready for operations.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Nancy Regan Leave a Comment

What Are Failure Effects in RCM? Understanding the Importance

What Are Failure Effects in RCM? Understanding the Importance

In this video, I dive into the concept of Failure Effects and why they’re important to the Reliability Centered Maintenance (RCM) process. A Failure Effect tells the story of what would happen if we did nothing to predict or prevent each Failure Mode, allowing us to properly assess the consequences and formulate the right maintenance strategies. I break down the essential components of writing a Failure Effect, including:

  • A description of the failure process from the occurrence of the failure mode to the functional failure
  • Physical evidence that the failure has occurred
  • How it adversely affects safety and/or the environment
  • How it affects operational capability
  • Specific operating restrictions as a result of the failure
  • Secondary damage
  • What must be done and how long it takes to repair the failure.

Understanding this zero-based approach is key, even though it can feel counter-intuitive to RCM Working Group members who are used to managing equipment proactively. That’s why an experienced RCM Facilitator is essential to guide the process. I also share an example of a Failure Effect in the video—feel free to pause and read through it.

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by George Williams Leave a Comment

Eliminate Defects & Unlock Reliability in Your Operation

Eliminate Defects & Unlock Reliability in Your Operation

Defects slow you down, cost you money, and wreak havoc on efficiency. It’s time to change that! In this video, George Williams breaks down Defect Elimination. Defect Elimination is a building block in the Operational Reliability domain, part of the Maintenance and Reliability Best Practices Framework.

⚙️ Identify defects early

⚙️ Take swift action to remove them

⚙️ Improve product quality and plant capacity

Stop reacting. Start eliminating. Watch now and take control of your operation’s reliability! Want to implement Defect Elimination in your operation? Contact us today! Let’s work together to improve your plant capacity and efficiency: www.reliabilityx.com/contact

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

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Recent Articles

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