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on Maintenance Reliability

A listing in reverse chronological order of these article series:

  • Usman Mustafa Syed — Aasan Asset Management 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

by Mike Sondalini Leave a Comment

The Role and Responsibilities of the Engineering Manager

The Role and Responsibilities of the Engineering Manager

Advice on the Key Duties and Responsibilities of the Modern Engineering Manager Role

The duties of the engineering manager role usually include capital project management and maintenance management, two vital aspects that must be done exceedingly well in an industrial operation.

[Read more…]

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

by Mike Sondalini Leave a Comment

Business Process Redesign the Plant Wellness Way

Business Process Redesign the Plant Wellness Way

A presentation slide set titled “Simpler Industrial and Business Process Redesign”. Presented by Mike Sondalini to The Institution of Engineers, Malaysia, Electrical Engineering Technical Division.

The presentation opens with examining three universal business problems:

  1. Wasted effort and resources
  2. Wrong business process for the purpose
  3. Wide and out-of-control process variation

He also explores the implication of the quality loss function and then incorporates the concept of maintenance work quality. Then Mike explore specific steps you can implement to improve the fundamental processes within your organization.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Nancy Regan Leave a Comment

5 Myths About RCM

5 Myths About RCM

Let’s dispel five common myths about reliability centered maintenance, including:

  1. RCM is a maintenance program.
  2. You must choose to do FMEA or RCM.
  3. You must choose to do CBM or RCM.
  4. If you do RCM, you must do it on all your assets.
  5. RCM has serious weaknesses in an industrial environment.
[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by George Williams Leave a Comment

Self Ownership Part 3

Self Ownership Part 3

Think back to the restaurant mess we talked about a few pages back, who was responsible?

The lesson for grown-ups (and more importantly executives and business leaders) from The Boy Who Cried Wolf is that the boy was at fault when he lied the first time, but the person who was really responsible for the sheep being lost was the shepherd who left his flock with a boy who he knew couldn’t be trusted.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Mike Sondalini Leave a Comment

The Instantaneous Cost of Failure from Breakdowns

The Instantaneous Cost of Failure from Breakdowns

The Instantaneous Cost and Failure from Breakdowns is Huge. When a failure incident occurs, there is a consequential loss of profits and amassing of costs. The cost of failure includes lost profit, the cost of repair, fixed and variable operating costs wasted during the downtime, and a myriad of consequential costs that surge through the business. They are all paid for by the organisation and seen as poor financial performance. The costs of failure cannot be escaped and are counted in fortunes of lost profit per year. Total defect and failure true costs are not normally recognised by managers, yet they can send businesses bankrupt. In the instance of a failure, all its costs and losses are automatically incurred on the business. These costs can only be prevented by not having the failure in the first place. This article explains the ‘Instantaneous Cost of Failure’ (ICOF) and introduces a proactive technique, ‘Defect and Failure True Costing’, that helps companies recognise and prevent this tremendous waste of money.

[Read more…]

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

by Mike Sondalini Leave a Comment

How to Write the Contents of the Lead Quality Manual Document

How to Write the Contents of the Lead Quality Manual Document

Read about the Requirements for the Content of the ISO 9001 Quality Manual Lead Document from which the rest of an ISO 9001 Quality System Cascades

An ISO 9001 Quality Management System requires a ISO 9001 Quality Manual that contains all the details of how your business is run to produce your products or services to a quality standard.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Nancy Regan Leave a Comment

5 CBM Facts

5 CBM Facts

CBM or Condition-Based Maintenance is a maintenance approach that includes these five facts:

  1. CBM doesn’t prevent failure.
  2. How often a CBM task is done is based on the P-F interval.
  3. How often something fails or the criticality of failure does not dictate how often a CBM task is performed.
  4. When it comes to CBM task intervals, what matters is how quickly falure occurs once the Potential Failure Condition is detectable.
  5. CBM is powerful because it allows impending failure to be identified before the failure occurs so that proactive action can be taken in enough time to manage the consequences of failure.
[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by George Williams Leave a Comment

Self Ownership Part 2

Self Ownership Part 2

A good mental framework to have is that instead of you pushing towards accomplishing goals, you think about what things you have to “pull” to get to the end game. The subtle shift in the thinking will position you to find more creative solutions to problems. A very frequent problem with management who doesn’t really know how to solve problems is saying things like “work harder”. If we just turn up the Hard Work Dial to 11, then the problems will go away, obviously. Instead if we looked at what is stopping the success and actively worked on removing those problems, we’d be able to remove the stress of failure without having to break the Hard Work Dial.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Karl Burnett Leave a Comment

1653-1774 The First Work Orders in the Royal Navy

1653-1774 The First Work Orders in the Royal Navy

A Bureaucratic Basis for Maintenance Management 

In 1653, “An Act for Constituting Commissioners for Ordering And Managing the Affairs of the Admiralty And Navy” established the responsibilities of the Admiralty and Commissioners of the Navy. The Commissioners were to make policy for building, fitting out, “repairing and preserving,” and “sale and disposal of old and unserviceable ships and vessels.” Another duty was to conduct a survey (i.e. an inventory) of the nation’s ships and naval stores, an element carried over from Monson’s Tracts in 1624.

[Read more…]

Filed Under: Articles, History of Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Screw Conveyor Auger Shaft Drive End Break

Screw Conveyor Auger Shaft Drive End Break

How operational loads break the drive shaft of a horizontal screw conveyor auger

Questions and queries asked following a screw feeder shaft breakage on a 15m long fertiliser dust transfer feed conveyor


If you have rotating shafts breaking at the drive-end of the auger shaft you may have a combination of bending and torsional fatigue. You are welcome to read the series of emails and responses below to a screw conveyor auger drive end failure.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

15 Ways to Remove Operational Risk

15 Ways to Remove Operational Risk

To increase reliability, you need to decrease the chances of failure occurring. Each chance of failure creates risk. Operating risk can be mitigated and managed by meeting all 15 Precision Maintenance excellence targets.

This list of precision maintenance excellence targets is how to ensure component parts, and the equipment they are in, always operate with optimal reliability. Each requirement must be met to the highest standard. By doing this your equipment and machinery are operating with the least microstructure stress possible and getting utmost reliability.

[Read more…]

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

by George Williams Leave a Comment

Self Ownership Part 1

Self Ownership Part 1

Here’s a common situation that most of us have experienced in our careers or education:

You’re working on a project with a tight deadline, the task is do-able, but difficult. Everyone has their specific tasks assigned, and the whole team is working together on a final document to turn in. Your section is the financial analysis portion of the project.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Mike Sondalini Leave a Comment

The Company That Made Its Machines Breakdown

The Company That Made Its Machines Breakdown

Abstract: Many companies struggle with constant plant and equipment problems despite doing the very best they know how to keep their plant and machinery reliable. Their real problem, which they cannot see for themselves, is that what is done in the company is completely wrong for creating highly reliable production equipment. If you cannot “see” how reliability is destroyed in your business, then you are doomed to suffer poor reliability and low uptime forevermore.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Bryan Christiansen Leave a Comment

Improve Critical Equipment Reliability and Reduce Maintenance Costs

Improve Critical Equipment Reliability and Reduce Maintenance Costs

In today’s competitive business environment, reliable equipment operation is crucial for uninterrupted operations and increased productivity. On the other hand, saving on maintenance costs can be a perilous path to tread.

Maintaining a balance between the two factors can have far-reaching effects, potentially even raising maintenance costs. The solution lies in optimizing equipment reliability, making it the bedrock of maintenance efforts.

It may be difficult to accelerate double-digit percentage cost reductions in some industries, such as pharmaceuticals and nuclear. Nonetheless, the primary focus should be on improving equipment reliability, which could lead to lower maintenance costs. [Read more…]

Filed Under: Articles, CMMS and Reliability, on Maintenance Reliability Tagged With: Maintenance Cost, Preventative Maintenance

by Mike Sondalini Leave a Comment

Example ACE 3T Maintenance Procedure with Inspection & Test Plan (ITP)

Example ACE 3T Maintenance Procedure with Inspection & Test Plan (ITP)

Here is a great example from an industrial operation of a maintenance procedure using an Accuracy Controlled Enterprise (ACE) 3T standard operating procedure (SOP) format. To make it better would need photos and/or videos included for critical tasks. 3T stands for Target-Tolerance-Test, which are the minimum criteria needed to specify maintenance task quality and prove compliance. The 3T’s are a simple maintenance work quality assurance technique we invented to maximise the chance of doing outstandingly high-quality maintenance work that brings you outstanding plant and equipment reliability.

[Read more…]

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

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