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You are here: Home / Archives for 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 Joe Anderson 2 Comments

Cultivating Excellence: The Art of Building a Reliability Culture

Cultivating Excellence: The Art of Building a Reliability Culture

In the realm of industrial operations, a culture of reliability isn’t just a preference; it’s a necessity. It’s the bedrock of efficiency, safety, and sustainability, providing the fertile ground for organizations to thrive and adapt in an ever-evolving world. In this blog, we will explore the methods and principles that guide the development of a reliability culture, the essence of operational excellence.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by André-Michel Ferrari 2 Comments

Evaluating Equipment Overhauls – are they Really Worth it?

Evaluating Equipment Overhauls – are they Really Worth it?

The Equipment Overhaul Paradigm

Overhauling equipment is expected to bring it to an “as good as new” state. But is this really the case in reality? Equipment will deteriorate over time and progressively lose its ability to function. No matter how extensive the overhaul, the equipment will unlikely be up to the level of “newness” as when it rolled out of the assembly line.  Sure, if you have this vintage automobile from the 1930s, and spend an absolute fortune on its overhaul, it might come close to being new again. But somewhere in the structure of this automobile, there will an element that is “as good as old” and vulnerable to imminent failure. Also remember that this vintage automobile is not out there generating revenue. There is no accountant running after you with regards to budget constraints or revenue increases. Where there is passion, cost might not matter.  

[Read more…]

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

by Mike Sondalini Leave a Comment

Crazy Risk Management with a Risk Matrix

Crazy Risk Management with a Risk Matrix

A risk management risk matrix can trick you into leaving high consequences uncontrolled and convince you it is fine to do nothing to reduce the impacts of failure. Whether you think a bad event cannot happen has no standing in Law. The likelihood of an adverse event is unimportant; only the resultant severity is how the Law will gauge your risk abatement efforts. Did you do ‘reasonably practicable’ risk control?

[Read more…]

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

by Nancy Regan Leave a Comment

T or F Must have Failure Data

T or F Must have Failure Data

False. Nearly all organizations do not have adequate historical data found in databases to successfully carry out an RCM analysis.

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Karl Burnett Leave a Comment

1833 Faraday and a HALT Experiment on Dry Rot

1833 Faraday and a HALT Experiment on Dry Rot

Accelerated life tests are used to help predict the rate of failure of components. Capacitors are frequent victims of accelerated life testing, and have a distant relationship with one of the earliest documented accelerated life tests: the unit of capacitance, the farad, is named for Sir Michael Faraday. 

Michael Faraday remains one of the most important scientists of all time. He made foundational discoveries in electricity, magnetism, and electrochemistry. Today, Faraday is less well known for documenting the Royal Navy’s results of accelerated life tests on dry rot of wood.

[Read more…]

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

by Mike Sondalini Leave a Comment

The Plant Wellness Way Difference 

The Plant Wellness Way Difference 

 The Plant and Equipment Wellness Way was designed to quickly create Operational Excellence success. You can only get the Plant Wellness Way from LRS Operational Excellence Consultants.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by James Reyes-Picknell Leave a Comment

Knowledge: Cornerstone of Human Capital

Knowledge: Cornerstone of Human Capital

Article first posted at Conscious Reliability by James Reyes-Picknell, Jesus Sifonte, and team.

Managing assets to make them deliver the products and services we need now and in the future is the essential purpose of Asset Management. However, Asset Management is more about obtaining value from assets than what you do to the assets. It is about utilizing assets to deliver value to your organization while attaining corporate goals. Human capital is an essential element of the whole asset management process from strategy to operation.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Joe Anderson Leave a Comment

Building Credibility: The Cornerstone of Professional Success

Building Credibility: The Cornerstone of Professional Success

Credibility, often described as the currency of trust, is a quality that sets the foundation for professional success. It’s the attribute that influences how others perceive your competence, reliability, and integrity. Whether you’re an individual striving to advance your career or a business aiming to gain the trust of your clients, credibility is your guiding star. In this blog, we’ll delve into the methods of developing and enhancing credibility to help you stand out in your professional journey.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by André-Michel Ferrari Leave a Comment

Getting Life Distributions from “Reliability” Handbooks? Be Careful!

Getting Life Distributions from “Reliability” Handbooks? Be Careful!

The need for life distributions

Maintenance and Reliability practitioners often need to find quick methods to estimate life distributions in order to get some urgent answers to a customer. The tempting solution and easy way out to this is to refer to a handbook or publication out there. Also known as “Reliability Data” handbooks. These publications would have “ready to go” life distributions.  However, this can come with multiple pitfalls listed as follows.

[Read more…]

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

by Mike Sondalini Leave a Comment

Dangers of Inventing Your Own KPIs to Measure Production Performance

Dangers of Inventing Your Own KPIs to Measure Production Performance

A certain Operations Manager started inventing production KPIs in order to measure reliability from a production perspective. So he got together his colleagues and they came up with this formula.

Reliability = Good Production / (Net Production Hours + Nominal Speed)

When asked to define ‘good production’, I was told that it was the saleable production remaining after losses such as speed losses, first time quality, downtime, change overs, etc. were taken off.

After 3 years of running TPM (Total Productive Maintenance) across 3 factories, they made the following observations. The mean time between failure (MTBF) of equipment in all 3 factories increased. The production volumes increased. However the Reliability remained flat. How can this be? Something is not right. Is the above formula incorrect?

Is there a better way to calculate Reliability from a production perspective?

[Read more…]

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

by Nancy Regan Leave a Comment

Should RCM Templates be used

Should RCM Templates be used

Maybe. Great care must be taken if any kind of template of failure mode library is used to complete an RCM analysis.

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by André-Michel Ferrari 2 Comments

Introduction to Barringer Process Reliability

Introduction to Barringer Process Reliability

Barringer Process Reliability – Your factory performance on a single page!

Barringer Process Reliability (BPR) was developed by Paul H. Barringer, a fellow reliability engineer “extraordinaire” and an outstanding mentor for myself and countless others in this field of practice.  BPR highlights operational issues. Not addressed and mitigated, those could have significant revenue impacts. A BPR analysis uses the Weibull probability plot which happens to be a very well-known tool in the field of Reliability Engineering. On one side of a sheet of paper only, the BPR plot can tell the true “story” on the operation.

[Read more…]

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

by James Reyes-Picknell Leave a Comment

RCM – 10 Myths Debunked

RCM – 10 Myths Debunked

Article first posted at Conscious Reliability by James Reyes-Picknell, Jesus Sifonte, and team.

What do you know about Reliability Centered Maintenance?

James Reyes-Picknell

Despite its well-documented successes, Reliability Centered Maintenance (RCM) has always drawn a lot of discussion and controversy. Much of it is because of a lack of understanding and “myths” generated to discredit RCM as a viable business solution. Here we attempt to fill in some of those gaps in understanding and debunk some of the myths.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Tips on Maintenance Job Priority Rating 

Tips on Maintenance Job Priority Rating 

 To help select which work orders to do first in situations of resource shortage many CMMS provide calculations for maintenance work order priority. Deciding maintenance work priority is a risk decision. The presence of risk totally changes the way to allocate maintenance job priority if you want to compare situations equally1. When you work with risk you cannot use a linear priority scale. Using linear priority ranking gives the wrong order of importance for doing maintenance work.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Miguel Pengel Leave a Comment

How to calculate optimal maintenance intervals

How to calculate optimal maintenance intervals

In a previous article we covered how to perform a detailed Weibull Analysis in Excel. The outputs from a Weibull analysis are important because we can use them for a variety of Reliability calculations such as when to most economically maintain assets.

A common mistake we see made is Reliability Engineers determining the optimal maintenance interval as the MTBF. This is incorrect as it assumes that you will have failed approximately 50-60% of the components before you have maintenance performed on them. (Sounds ridiculous when you say it that way right!?)

[Read more…]

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

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