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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 Karl Burnett 1 Comment

The Maintenance Career of Diarist Samual Pepys

The Maintenance Career of Diarist Samual Pepys

Samuel Pepys is famous for keeping a diary from 1660 to 1669. He recorded details of everyday life in London during the Restoration period, including firsthand accounts of the plague and the Great Fire of London. Pepys spent most of his career managing the Royal Navy’s logistics and shipbuilding programs during the second, third, and fourth Dutch wars. From 1673 to 1679, he was the Secretary for the Admiralty. He fought bureaucratic waste and endemic bribery while building the so-called “Thirty New Ships” of 1677. After infighting between political factions, Pepys resigned in 1679 to face trial for corruption himself.

[Read more…]

Filed Under: Articles, History of 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

How Industrial Operations use Plant Wellness Way to get World-class Production

How Industrial Operations use Plant Wellness Way to get World-class Production

An Executive Report for CEO’s, Executives, and Senior managers in industry and manufacturing.

Utmost operating profits, lowest maintenance costs, world class reliability, & outstandingly effective physical asset management the Plant Wellness Way

Let a Plant Wellness Way EAM System-of-Reliability halve your Annual Maintenance Costs

In the Plant Wellness Way (PWW) you do nothing to your business until you have total confidence that what you do, and how it will be done, will be extraordinarily successful.

[Read more…]

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

by George Williams Leave a Comment

Self-Leadership Part 2

Self-Leadership Part 2

Self-leadership is the constant step of focusing on forward motion, and taking out your compass to make sure you’re always still heading north. Constant action in the wrong direction can be just as harmful as standing still, sometimes worse.

This is a constant three step process. As your journey keeps moving forward, you need to keep checking your sails to make sure the wind is moving you in any direction: this is self-leadership.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Bryan Christiansen Leave a Comment

How To Use CMMS To Support FRACAS Methodology

How To Use CMMS To Support FRACAS Methodology

Organizations can face a wide range of failure problems, ranging from technical to process failures. These common failures include equipment breakdowns, product failure, quality issues, and environmental incidents. These failures typically require a more systematic approach. This involves failure tracking and corrective measures implementation — in comes the FRACAS methodology. 

The FRACAS process tracks and manages failures and problems in products or systems. Almost every industry uses this approach. The goal of FRACAS is to uncover the cause of errors and take corrective action to avoid similar occurrences in the future. The process of FRACAS involves failure documentation, conducting failure examination, corrective measures implementation, and continually seeking ways to enhance the process. [Read more…]

Filed Under: Articles, CMMS and Reliability, on Maintenance Reliability Tagged With: CMMS, Failure Reporting Analysis and Corrective Action System (FRACAS)

by James Reyes-Picknell Leave a Comment

Do you have a PHB (Pointy haired boss)?

Do you have a PHB (Pointy haired boss)?

Do you have a PHB, “Pointy haired boss”? If you’ve seen any Dilbert comics, then you know who I mean. Dilbert is an engineer too. The PHB is oblivious to the reality around him, only interested in how things look, and impossible to get to with Dilbert’s good ideas.

The comic is popular, especially among engineers, for a good reason. Scott Adams (Dilbert’s creator) knew that the technical world is full of frustration because of the relationship that engineers have with their own PHBs. Technicians, supervisors, superintendents, and managers in maintenance and reliability almost always have technical backgrounds. I’d hazard to say that we’ve all had PHBs at some point.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Mike Sondalini Leave a Comment

When To Use Stainless And Alloy Steel In Place Of Plastic Or Carbon Steel Items

When To Use Stainless And Alloy Steel In Place Of Plastic Or Carbon Steel Items

When To Use Stainless And Alloy Steel In Place Of Plastic Or Carbon Steel. There are many times when it is false economy to use carbon steel and plastic items. It is often better to use stainless and alloy steels instead. They last longer and deliver a lower life cycle cost.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

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 George Williams Leave a Comment

Self-Leadership Part 1

Self-Leadership Part 1

Let’s do a quick recap of where we’ve come from. First we had to figure out where you are on your journey to success, in a totally honest way, which we covered in the chapter of Self-Awareness.

Next we had learned how to hold ourselves accountable for what got us to where we are today. We discussed how to create a personal development plan to map out our different responsibilities in life, what those mean in specific, day-to-day terms, and how to monitor and measure our success on aiming for and achieving those goals.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Mike Sondalini Leave a Comment

Rate of Occurrence of Failure

Rate of Occurrence of Failure

The Rate of Occurrence of Failure (ROCOF) curve is the sum of all the individual component failure curves across the service life of an asset. As shown below, it looks like a bathtub, giving it the nickname, a bathtub curve.

Equipment reliability is malleable by choice of policy and quality of practice.

[Read more…]

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

by Bryan Christiansen Leave a Comment

Why Total Productive Maintenance Is The Answer To Reliability-Centered Culture

Why Total Productive Maintenance Is The Answer To Reliability-Centered Culture

Despite their shared emphasis on maintenance, Total Productive Maintenance (TPM) and Reliability Centered Maintenance (RCM) are not competing strategies.

Manufacturers can create a powerful synergy to leverage the strengths of each if they understand their respective strengths. Such a combination leads to exceptional reliability, cost-effective maintenance, and improved corporate culture – if implemented successfully. [Read more…]

Filed Under: Articles, CMMS and Reliability, on Maintenance Reliability Tagged With: Reliability Centered Maintenance (RCM), Total productive maintenance

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

Is it Time to Kill Your Organization to Build a Better One?

Is it Time to Kill Your Organization to Build a Better One?

Every organization and organism’s performance is limited to the capability of its design. If you want better business results, then get or build a new organization with systems designed to naturally deliver the outcomes and profits you want. Nothing else you do will ever work as well!

[Read more…]

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

by Karl Burnett Leave a Comment

Failure Modes of Lead Hull Sheathing Explored by the Royal Navy, 1670-1690

Failure Modes of Lead Hull Sheathing Explored by the Royal Navy, 1670-1690

Preservation and repair are as old as sailing, but a written record of how this was managed has not always survived. One failure mechanism that has affected wooden vessels for centuries is shipworm – a mollusc that drills deep holes into the hull. 

Shipworm was common in the Mediterranean, so there is a long record of means to combat it. A shipwreck in Kyrenia has been dated to somewhere between 384 BC – 288 BC. The hull was covered with hammered lead sheathing to protect it from shipworm. Archaeological examination concluded that over its lifetime, the ship had received four major repairs, and in-service modification. The Kyrenia ship first sailed with no sheathing, but wooden sheathing was added. Later, lead sheathing was used. (Steffy p. 95)  Archeologists have also observed the use of oche on ship hulls in the Mediterranean and debate if the purpose was preservation of the hull. Several Greek and Roman ships with lead sheathing have been studied. By 1514, Spain was using lead sheathing. An Englishman who had served the Spanish crown sheathed a small English squadron with lead sheathing in 1553. (Wilkinson p. 132)  In 1624, Monson wrote in Monson’s Tracts that the Spanish and Portuguese used lead sheathing, but that it was “not durable” so not in use in England.

[Read more…]

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

by Mike Sondalini Leave a Comment

Two Ways to Get High System Reliability

Two Ways to Get High System Reliability

There are only two ways to get high system reliability if you want a highly reliable system. Equipment in an operation can be configured in series or in parallel. In series, one item connects sequentially to the other. In parallel, each item is arranged as a companion, where one duplicates the other.

A series arrangement needs exceptionally reliable individual equipment to get a highly reliable system. A parallel arrangement can form a highly reliable system even if individual equipment has poor reliability.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

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