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Maintenance Management

This Maintenance Management article series introduces and discusses maintenance management strategies, systems and processes for optimizing plant and equipment maintenance, maximizing equipment uptime, and for minimizing operating costs.

The purpose of this Maintenance Management series is to provide reputed, useful content that improves an operation’s and organisation’s maintenance effectiveness.

The Maintenance Management series of articles are provided with permission of  Lifetime Reliability Solutions.

NOTE: The series does not include coverage of related commercial or vendor software or database management applications.

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 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 Mike Sondalini Leave a Comment

The Connection Between Equipment Risk and Equipment Reliability

The Connection Between Equipment Risk and Equipment Reliability

A slide deck of a presentation made by Mike at the SIRFRt WA Maintenance Roundtable November 2011.

Mike goes into depth with risk quantification, plotting techniques, along with connecting maintenance related risk to business risk levels. The presentation also explores using reliability as an element in the risk equation and discusses a few different ways to minimize risks.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Maintenance Planning and Scheduling for World Class Reliability and Maintenance Performance

Maintenance Planning and Scheduling for World Class Reliability and Maintenance Performance

3-Day Training Course

Day 3 Maintenance Planning and Maintenance Scheduling Slides with Complete Explanations

Welcome to the final day of the Maintenance Planning and Scheduling for World Class Reliability and Maintenance Performance 3-Day Training Course. I hope that you enjoyed Days 1 and 2 and found the maintenance, reliability, work quality control and work planning concepts they contained useful.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Condition Monitoring that Supports Precision Maintenance

Condition Monitoring that Supports Precision Maintenance

A slidedeck by Mike Sondalini for the SIRFRt CM & Lube Forum 2010 Conference.

Mike examines precision maintenance and the supporting condition monitoring with definitions, processes, and examples.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

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

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

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

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

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

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

by Mike Sondalini Leave a Comment

How Profit Contribution Mapping Turns Wasted Money into Outstanding Operational Productivity and Profits

How Profit Contribution Mapping Turns Wasted Money into Outstanding Operational Productivity and Profits

Value Stream Mapping is a business process improvement tool. It derives from the Toyota Production System where it was used to identify the seven wastes in a production process. It is now used across all business processes because the principle of finding and removing waste applies throughout every business.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Getting High Equipment Reliability

Getting High Equipment Reliability

These are the slides from Mike’s conference presentation at the SIRFRt CM & Lube Forum 2008 Conference.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Day 2 Maintenance Planning Slides with Complete Explanations

Day 2 Maintenance Planning Slides with Complete Explanations

Welcome to Day 2 of the Maintenance Planning and Scheduling for World Class Reliability and Maintenance Performance 3-Day Training Course. I hope that you enjoyed Day 1 and found the maintenance and reliability concepts it contained useful.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Annex SL Structure for ISO 55001 Asset Management Documentation in a EAM System Manual

Annex SL Structure for ISO 55001 Asset Management Documentation in a EAM System Manual

WHEN YOU BUILD AN ASSET MANAGEMENT SYSTEM FOR ISO 55001 CERTIFICATION THE ISO 55001 EAM SYSTEM MANUAL NEEDS TO COMPLY WITH THE ANNEX SL DOCUMENT STRUCTURE.

Here’s a practical way to create an ISO 55001 EAM system manual that covers all bases for both ISO 55001 certification and Annex SL requirements. Annex SL stipulates ten sections that every management system built to an ISO management system standard must contain. But matching legacy enterprise asset management 9EAM) system documents to Annex SL sections can be tricky.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

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Headshot of Mike SondaliniArticles by Mike Sondalini
in the Maintenance Management article series
articles provided with permission of Lifetime Reliability Solutions

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