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Miscellaneous Articles on Maintenance Management

If you have an article to contribute to this list, please mail me.


1999 Maintenance Salaries 1999 Maintenance Technology magazine survey
1999 Plant Maintenance Salary Survey - Results
2000 "Maintenance and the Internet" Survey Results This survey of Internet usage by Maintenance professionals was conducted on the Plant Maintenance Resource Center website between March and June 2000
2000 Plant Maintenance Salary Survey - Results
2001 Plant Maintenance Salary Survey - Results
2002 Plant Maintenance Salary Survey - Results
2003 Maintenance Salary Survey Results Results of the 5th annual Plant Maintenance Resource Center maintenance salary survey - requires free Adobe Acrobat Reader for viewing.
2004 Maintenance Salary Survey Results Results of the 6th annual Plant Maintenance Resource Center maintenance salary survey - requires free Adobe Acrobat Reader for viewing.
2005 Maintenance Salary Survey Results Results of the 7th annual Plant Maintenance Resource Center maintenance salary survey - requires free Adobe Acrobat Reader for viewing.
2006 Maintenance Salary Survey Results Results of the 8th annual Plant Maintenance Resource Center maintenance salary survey - requires free Adobe Acrobat Reader for viewing.
5 Points to Failure-Free Design In September of 2002, a stamping plant located in the Chicago area was having press availability problems caused by an electronic transfer feed (ETF)system. The ETF is used to transfer parts between the various dies in the press. The plant stated that the ETF was in a "death spiral" and they could not meet the current production schedules. Overtime and maintenance dedicated to keeping the ETF running was consuming the budget, and the engineering group was being held accountable for all of the overtime associated with the ETF failures. In this case study, Doug Malcolm of DRM Techologies outlines how these problems were overcome using a "5 Points to Failure-Free Equipment Design" - requires free Adobe Acrobat Reader for viewing.
A Leader Without A Vision Is Only A Boss
A Life Cycle Cost Summary This paper, from Paul Barringer of Barringer & Associates, Inc., describes how the Life Cycle Costing economic model provides better assessment of long-term cost effectiveness of projects than can be obtained with only first costs decisions. - requires free Adobe Acrobat Reader for viewing.
A Maintenance Leader Who Wants to get out of the Repair Business?
Achieve Best in Class Reliability The continued high performance of assets is essential for refineries and petrochemical facilities that need to meet production demands, eliminate defects, achieve safety and environmental regulations and initiatives, limit lost production opportunities, and reduce costs. The goal is to move from reactive to proactive maintenance strategies that maximize up-time and minimize equipment failure. To that end, companies have focused a great deal of time and money deploying the best technology and subject matter experts, only to find themselves stuck in a reactive mode. A case in point was recently made by a major petrochemical executive, who commented, "We bought the best point solutions. Then, we hired respected experts to employ the point solutions. And yet, years later, we are still 60% reactive."
Action Teams: Reliability Improvement on the Front Lines - requires free Adobe Acrobat Reader for viewing.
Adjustments - Friend or Foe Adjustments are an excellent way to get an equipment set up to standard (ie. Manufacturers specification). They also, however, can be used very effectively to get equipment out of standard. How many times have we seen a situation at shift change where an operator takes over a machine or a line and the first action they take is to change settings even though the machine has been performing well over the previous shift? How many times have we walked past equipment where guards on machine components have nuts missing, holes in machine frames where something should be or places where things should be attached and are not? Were these issues deliberately left like this or have things gone missing and we just don’t know where or why they have.So what can be done to overcome these issues? - requires free Adobe Acrobat Reader for viewing.
Alarm Management Blunders: Avoiding 12 Costly Mistakes Takes a look at how alarm management solutions can significantly improve plant safety, reliability, and profitability, but will only succeed if they are implemented properly. Mr. Marvan explains a recommended project methodology, and how to avoid some common mistakes in order to achieve an effective and successful alarm management project that will enable personnel to be more productive and plants run more reliably. - requires free Adobe Acrobat Reader for viewing.
Alcoa All Fired Up About Reliability Can you feel the heat? Every employee at this plant does. But instead of awaiting a demise that seemed imminent, maintenance and operations personnel have stepped forward and taken action.
An Introduction to the Maintenance Scorecard This is a longer article than our normal article - in fact, it is the first chapter of Daryl Mather's new book - The Maintenance Scorecard. This book tackles the issue of alignment of asset management with other areas of corporate activity, and this first chapter sets the scene - outlining the key issues, and explaining how a structured approach to measuring maintenance performance assists with creating this alighment. - requires free Adobe Acrobat Reader for viewing.
Application of the Tools of Taking Multicriteria Decisions to the Management and Administration of Projects in Stoppages of Chemical Plants Processes The objective of this article is to examinate the utility of the techniques of taking decisions and the way of applying them in the management projects and administration of stoppages of plants of chemical processes.
Are You a Take Over Target For Contract Maintenance? - requires free Adobe Acrobat Reader for viewing.
Asset Management Covers the basics of Asset Management - what is it, where has it come from, making it work, and the Asset Management toolkit. - requires free Adobe Acrobat Reader for viewing.
Asset Management - Latest Thinking An Asset Manager has to be all things to all people. He or she is the point of contact between business objectives and the considerable complexities of technical and human issues. With business performance accountability and technical responsibility, the Asset Manager is a professional translator – converting options such as new technology opportunities, maintenance strategies, design changes or asset replacement decisions into business or economic language, often with little or no hard data to work with. The newly emerging management science of Asset Management is trying to deal with these requirements; equipping engineers to become businessmen, and introducing some structured methods for handling reliability, performance, maintenance, safety, environmental, staff motivation and other headaches. - requires free Adobe Acrobat Reader for viewing.
Asset Management at the Millennium A theoretical background of asset management is missing; most of the literature on maintenance optimisation models does not fit in an engineering mindset, being too specialist and lacking an overall, systems engineering viewpoint. Reliability engineering is hardly ever integrated in the mechanical engineering curriculum and maintenance managers still lack effective decision support techniques.
Asset Management Benchmarking to Deliver Sustainable Improvements This paper reports on how significant improvements can be achieved in the water utilities, UK and abroad, by benchmarking current performance data against specific measures and performance objectives using Best Appropriate Practices, (BAPs) - requires free Adobe Acrobat Reader for viewing.
Asset Management Decision-Making - requires free Adobe Acrobat Reader for viewing.
Asset Performance for Profitability Mainstream Maintenance publications consistently highlight why maintenance makes good business sense but the message had not been widely understood by business management. In this article, Angelo Agresti of Asset Capability Management offers some reasons why the message has not been understood, and suggests a framework which can be used to realise the benefits of good maintenance practice - requires free Adobe Acrobat Reader for viewing.
Asset Utilization - A Metric for Focusing Reliability Efforts This article explores the concept of asset utilization in more detail by addressing the four components: people, processes, technology and information, that comprise effective asset utilization programs. - requires free Adobe Acrobat Reader for viewing.
Automated Bearing Wear Detection This article written by Alan Friedman of DLI Engineering describes a methodology for automatically detecting and diagnosing rolling element bearing wear. The techniques involved have been proven in over 15 years of use in a huge variety of environments, machine types and applications. The techniques involved in diagnosing bearing wear are described in detail and supported by a set of example graphs and an annotated diagnostic report.. - requires free Adobe Acrobat Reader for viewing.
Back to the basics - Now what were they again? This paper calls on maintenance managers to sit back and take a fresh look at the maintenance organisation and examine the maintenance business processes. The nature of maintenance business processes is examined and methods discussed to ensure adequate design and development of processes to suit the business needs and ensure maintenance is effective, efficient, economical, safe and performed in a manner that ensures asset integrity and the continual provision of productive capacity.
Best Performers Observations of what the best performing organizations do differently than other organizations
Best practices in Fire Fighting Ever been to the emergency room in a hospital? When someone comes in with a broken leg they roll over the orthopedic cart with all the tools and materials for broken bones. They cannot fix everything with what is on the cart but they can stabilize almost everything and fix upwards of 90% of the emergencies.
Breakdown Blues Breakdowns are not only not ok but there are costs way above the repair costs.
Business Based Maintenance - The way to maintenance effectiveness Many manufacturing managers feel that maintenance is not contributing appropriately in the support of production goals. And because these manufacturing managers don’t really know how to successfully improve maintenance, their mindset is to limit maintenance costs by cutting expenditures, therefore striving to minimize the negative impact maintenance costs have on plant performance. The demands being placed on maintenance are considerable and are escalating constantly. - requires free Adobe Acrobat Reader for viewing.
Business Driven Reliability at Mobil's Beaumont Refinery - requires free Adobe Acrobat Reader for viewing.
Catalyst Paper adopts the Ivara Reliability Solution Catalyst Paper adopts Ivara Asset Reliability Process as the Strategy to Improve Mill Performance by up to 3% in Paper Machine Efficiency - requires free Adobe Acrobat Reader for viewing.
Changing Maintenance Practices An outline of 12 areas of Maintenance Best Practice
Characteristics of World Class Operational Excellence This is the first of two articles – Design for Maintenance Prevention – describing the core aspects of ‘cradle to grave’ Lifecycle Asset Management Process. - requires free Adobe Acrobat Reader for viewing.
Characteristics of World Class Operational Excellence - Steps Necessary to Optimize Equipment Lifetime Performance This is the first of two articles - Design for Maintenance Prevention - describing the core aspects of ‘cradle to grave’ Lifecycle Asset Management Process. - requires free Adobe Acrobat Reader for viewing.
C'mere, Kid! Being alone as a new manager without the help of experienced senior guidance can be frightening to say the least! Today, young people who are trying to master management positions in maintenance have two things in common - requires free Adobe Acrobat Reader for viewing.
Collaborative Production Management in the Process Industries Takes a look at how industry is overwhelmed with data and needs to shift focus from data collection to using the data to make intelligent decisions. Using Key Performance Indicators, Tree Mapping Technology, and looking at daily workflow, Mr. Brown explains how operations can leverage their process data to optimize plant performance and improve safety. - requires free Adobe Acrobat Reader for viewing.
Competitive Advantage by Ensuring Equipment Reliability Cummins India implemented an innovative approach to retain and enhance their business profitability. - requires free Adobe Acrobat Reader for viewing.
Components of a Comprehensive Chiller Replacement Analysis After presenting all the conversion, retrofit or replacement options available, the owner of your company has made the decision to replace a chiller. The next stage in your investigation should be a chiller replacement analysis. This article outlines the key components of this analysis.
Contractor Management Controls There’s a great story about a town with a clock tower that rang every day at exactly noon. The man in charge of the tower called City Hall each morning to confirm the exact time before adjusting the clock. Everyone in the town knew for certain when the tower clock rang; it was straight-up 12:00 noon. One day, after many years on the job, the bell tower man happened to ask the city hall clerk how he always knew the exact time. "That’s easy," the city hall clerk replied, "I rely on the clock tower."
Cost Cutting? Let the pros do it! This is a story about cost cutting by the people who maintain your buildings, clean your floors, and keep your grounds neat. You can follow their example and involve your workers in cost cutting.
Cost Risk Optimisation - requires free Adobe Acrobat Reader for viewing.
Creating a Successful Corporate Maintenance Council Most large, multi-plant companies have launched corporate “Maintenance Councils” in the past decade. While some have achieved a significant success, most are still floundering for direction and concrete results. In this article from Bradley Petersen of SAMI, he explains the differences that lead to success. - requires free Adobe Acrobat Reader for viewing.
Creating an Asset Health Care Program A key question in operating any plant is this: Are we doing the right amount of maintenance? Are we doing the right type of maintenance? This article from Bradley Petersen of SAMIgives a step-by-step method to systematically develop an asset healthcare program, resulting in the necessary reliability to meet your business plan, at the lowest cost. - requires free Adobe Acrobat Reader for viewing.
Current Best Practices - An Educational Journey The concept of Best Practice is easy to describe and discuss – the more difficult part is determining your path towards Best Practice and more importantly, sustaining standards and developing a continuous improvement culture.
Deferred MaintenAxe Song - on benefits of Deferred Maintenance
Defining Asset Management Asset management is a term that has been getting a lot of press recently. The term implies many things to many people, and there is no industry standard for application. This article, from Bradley Peterson of Strategic Asset Management Inc. defines asset management as a global management process through which we consistently make and execute the highest value decisions about the use and care of our assets. - requires free Adobe Acrobat Reader for viewing.
Designing for the Life Cycle
Developing a Partnership Between Maintenance & Operations - Where to Start? Maybe you’re an experienced maintenance professional, or just starting out in your career; you’ve been to training seminars, attended some conferences, and maybe even participated on a best practice visit (a.k.a. industrial tourism trip). You’ve read, heard, or visited plants making significant gains in reliability performance, and now you want to do the same at yours. Where do you start? - requires free Adobe Acrobat Reader for viewing.
Doing it Right You wouldn’t believe what Proactive really means? When you care to listen, take good notes, and produce 150% of your requester’s needs. When you do it right the first time, you cement a strong relationship, and a positive dependence that is geometrically larger than your native value to the organization. This is my dedication to the trivially innumerable perfectionists. - requires free Adobe Acrobat Reader for viewing.
Effective Maintenance Management - Risk & Reliability Strategies for Optimizing Performance Maintenance can mean different things to different people. Quite often, senior managers and accountants see maintenance as a cost burden that should be minimized. At the working level, some of us see it as a set of preven­tive, corrective, or breakdown rectification activities. Some classify it as reactive or proactive work. To still others, it means predictive, planned, or unplanned activity. All these are merely the various dimensions of mainte­nance.
E-Mail: the Most Used and Least Effective Communications Tool
Engaging the Entire Organization in Improving Reliability - requires free Adobe Acrobat Reader for viewing.
Ensuring Asset Integrity - A Risk Based Approach - requires free Adobe Acrobat Reader for viewing.
Equipment Reliability: Getting Fast, Focused, Sustainable Results What is the secret of generating revenue and lowering operating costs fast? Focus, focus, focus! Focus your reliability efforts on the critical few pieces of equipment in your production process flow. Look for the constraints first. This will lead to improved throughput and revenues. If the causes are related to equipment performance and reliability, then follow this simple process.
Establishing Continuous Asset Management Improvement The new British Standard PAS-55 defines what a physical asset management system needs to include, but how do companies stack up against this model? This article looks at the best practices, the practical challenges and some of the key enablers required to put the whole jigsaw together - requires free Adobe Acrobat Reader for viewing.
Evolution of the Precision Paradigm Exactly what does a Precision environment look like? As humans, are we really capable of attaining such an environment?
FAA FY01 Aviation Maintenance Human Factors Program Review Summary of the findings of research projects in the Aviation Maintenance Human Factors program, funded by the FAA - 2001 - requires free Adobe Acrobat Reader for viewing.
FAA FY02 Aviation Maintenance Human Factors Program Review Summary of the findings of research projects in the Aviation Maintenance Human Factors program, funded by the FAA - 2002 - requires free Adobe Acrobat Reader for viewing.
Finding the Elephant in Maintenance In the world of manufacturing and facilities management, we often get called upon to find ways to improve maintenance. Consider these basic steps for sustainable improvements.
Finding the right mix of costs, risks & performance Cost/Risk decisions range from evaluating a proposed design change, determining the optimal maintenance or inspection interval, when to replace an ageing asset, or which and how many spares to hold. - requires free Adobe Acrobat Reader for viewing.
Five Key Ways to Improve Reliability There are many reasons why systems fail to achieve their requirements. However, there are several reasons for failures that repeatedly surface. Five of these reasons are: (1) failure to design in reliability early in the development process; (2) inadequate lower-level testing; (3) relying on predictions instead of conducting engineering design analysis; (4) failure to perform engineering analyses of commercialoff- the-shelf (COTS) equipment; and, (5) lack of reliability improvement incentives. - requires free Adobe Acrobat Reader for viewing.
Focus on Cost Reduction
Focus on Reliability
Fundamentally Rethinking Maintenance and Reliability M&R programs-of-the-month come and go, each being the silver bullet designed to outdate all other practices. Unfortunately, they rarely work and are rarely sustainable. We need to fundamentally re-think our M&R strategies as we approach this "perfect storm" of skills shortages. So where do we start?
Guaranteed Maintainability Nine areas to consider in the design and specification of new assets
Guideline to Good Practices for Maintenance Control This guide is intended to assist facility maintenance organizations in the review of existing methods and in the development of new methods for evaluating maintenance facilities, equipment, and tools. - requires free Adobe Acrobat Reader for viewing.
Hazardous Area Installation Management This White Paper is an attempt to help engineers and managers, not only in the UK , but also elsewhere, to have a clear understanding of this subject and address the key issues involved.
Headcount Reduction A message from corporate declared that the maintenance staff was to be cut by 15% within 30 days.
Health care of humans and maintenance of equipment, is there a correlation? If we maintain equipment right, we will benefit fewer failures and break downs and a longer technical equipment life. Many case studies have proven this fact. In previous columns I have shown case studies covering the strong correlation between high reliability and low maintenance costs of equipment. In this column I will discuss another aspect of maintenance and how this might prove the same phenomenon including longer life.
Here Lies Troubleshooting courtesy of Reliability Center, Inc.
Hidden Profits: They're Closer Than You Think Finding new profits calls for new ways of looking at your business. A Midwest manufacturer with sales of $45 million unlocked 19 different changes to their business that generated $6 million in new profits in the first year. How were they able to identify these opportunities?
How OCE Impacts Your Bottom Line - requires free Adobe Acrobat Reader for viewing.
How to Change from a Reactive Organization to a Proactive Organization
How wide is your vision? Narrow vision is a problem that we see through out our industry. People with tunnel vision prepared to take action, with no thought about the consequences of their actions
Human error as a factor of corrosion failures When all the human errors and management system deficiencies are included, the typical machine breakdown is the result of somewhere between five and ten significant contributors
Human error in aviation maintenance: the years to come Human decision-making in operational contexts lies at the intersection of production and safety, and is therefore a compromise.
Human Factors in Maintenance: Working To Reduce Errors A summary of several seminars on human factors in maintenance (HFIM)
Human Factors Process for Reducing Maintenance Errors An introduction to the the Maintenance Error Decision Aid (MEDA) process offered by Boeing
I Dreamt That I Had This Discussion With The Treasurer Of General Motors I Dreamt That I Had This Discussion With The Treasurer Of General Motors and This Is What I Told Him That He Had To Know About Plant Maintenance and E-Commerce - requires free Adobe Acrobat Reader for viewing.
Implementation of a Quality Management System for Coal Handling Plant of Thermal Power Station Effective management of Coal Handling Plants requires the coordinated integration of Operations, Maintenance, Engineering support, Taining, and Administration in order to supply a reliable flow of fuel to boiler to avoid failure of energy supply to consumers. To fulfill this need, the structure of management is process-centered. It should also be linked to a Quality Management System (QMS), which has particular management characteristics
Implementing and Achieving Rx What is Reliability Excellence? - requires free Adobe Acrobat Reader for viewing.
Improve Basic Work System First Many organizations spend too much time searching for - and starting implementation of - new reliability and maintenance concepts, and very little time on implementation and improvements of what they just started
In Maintenance, Two Plus Two Can Equal Eight Most maintenance departments profess to be convinced of the need for planning and scheduling and condition based maintenance. However, the benefit of using them together seems to be shrouded in mystery. Let’s open the hood and look at how they work together to produce results far exceeding that of the sum of the benefits of each used alone.
Integrated Machinery Management This paper proposes a holistic, integrated approach to machinery management. Such a program is comprised of four major elements. There must be a systematic planned maintenance system for routine maintenance and condition assessment. A system must be in place to insure needed spares are available without carrying excessive inventory. Most importantly, a measurement system must collect necessary data and present it to management in such a way that they understand their problems and what action to take.
Joint Fleet Maintenance Manual Official Joint Fleet Maintenance Manual from the US Navy
Journey to Maintenance Excellence - Introduction An introduction to this series of 5 articles by Pete Peeters of the Maintenance Excellence Institute which presents a strategic approach to Maintenance and Reliability Improvement. - requires free Adobe Acrobat Reader for viewing.
Journey to Maintenance Excellence - Maintenance is For Ever This article is the first in a series of five offered by Pete Peeters of the Maintenance Excellence Institute. It defines the need for long-term continuous reliability improvement (CRI) within the business of maintenance and physical asset management. It sounds the alarm to support maintenance leaders in their quest to maintain facilities and equipment with diminishing funds while often gaining new production assets and facilities along with new maintenance requirements for these physical assets via new minor/major additions or acquisitions. It also strives to explain how four very basic but interrelated challenges can almost exponentially grow the scope of overall maintenance work requirements. - requires free Adobe Acrobat Reader for viewing.
LCC Life Cycle Cost The concept of Life Cycle Cost (LCC) is not well practiced in many organizations because we are driven by shortsightedness and a focus on short term cost reductions instead of a focus on what drives cost.
Lean Maintenance for Lean Manufacturing How does one "fix a machine so it doesn't break down again"? Answer: To prevent downtime from happening before it occurs, you must eliminate the basic stresses that cause the downtime. What is needed is a methodology for protecting computers, automation controllers, PLCs, CNC machines, etc. and protect their electronic and hydraulic control systems from the stresses that cause malfunctions and failures. Howard C. Cooper of Amemco has been applying this methodology and perfecting it since 1977. He calls it "Lean Maintenance for Lean Manufacturing."
Lean Manufacturing - Using costs to drive improvement projects An article about Lean Manufactruing using costs to quantify wastes, plan & simulate cost results, and track technical improvements' impact on cost. - requires free Adobe Acrobat Reader for viewing.
Lean Organizations Must Have Reliable Equipment Many of today’s business leaders interpret "lean" as "downsizing"and make the mistake of reducing headcount. That is not the intent of "lean." Explore what lean is and what it isn't.
Let's Kill Wrench Time Studies! Why is a wrench time study a poor business practice?
Life cycle asset management guide - requires free Adobe Acrobat Reader for viewing.
Maintainability, an Opportunity for Significant Improvement
Maintaining a Strong Performance in the Mill In a bid to improve reliability and performance, mills can chose one of two ways to carry out their maintenance tasks, both of which lead to higher production throughput and lower costs.
Maintaining Substation Reliability Using an Asset Management Strategy As a result of economic pressures caused by deregulation, utilities are looking at new ways to approach the business of operating and maintaining their assets. In particular, one utility has taken a look at managing their substation assets as if they were stocks in a portfolio. Like financial managers who try to maximize return-on-investment for each asset in a client's portfolio, substation maintenance managers try to maximize the value of each task. This is done through careful consideration of the condition of each asset and its ability to produce revenue. Such an approach requires a deep understanding of both the criticality and the reliability of each asset. - requires free Adobe Acrobat Reader for viewing.
Maintenance - A Business Centered Approach There is not doubt that Maintenance remains one of the very few business areas where significant increases to company profits can be achieved
Maintenance and the Blue Crab Suppose, just suppose, that the autotomy escape mechanism of the Blue Crab could in some way be compared with Preventive and/or Predictive Maintenance. Could it just possibly be that the Blue Crabs sensing of imminent danger have a natural form of something like PM/PdM? - requires free Adobe Acrobat Reader for viewing.
Maintenance Crisis Song The Maintenance Crisis Song has struck a chord in the industry due to its message that younger generations are not considering the maintenance and engineering fields as career paths while the majority of skilled workers are reaching retirement ages, meanwhile current equipment ages, requiring more maintenance needs, and newer equipment introduced are increasingly more sophisticated and require higher level of skilled care.
Maintenance Data Management in Framework of Supportability Analysis The maintenance system can be analyzed in differrentiated manners. It can be considered as a part of enterprise information infrastructure, too. This paper attempts to summarise some of the most important principles of maintenance data management in the field of supportability analysis. Supportability analysis has viewed as the process of recognizing support requirements for a new system with the purpose to ensure that the technical system will perform as intended. The paper also is directed toward exploring what the maintenance data are to the logistician. It includes additional considerations relating to elements such as product-service bundle database and logistics information system. In short, the paper describes maintenance aspect of the concept of through life information management.
Maintenance Management As a Quality Process This article describes Maintenance as a Quality Management process, particularly focusing on the Plan-Do-Check-Act cycle.
Maintenance Management Informatics This paper presents general notion of info systems in maintenance management. It departures from basics of modelling a system such as an economic enterprise, business or integral asset to demonstrate how an industrial system can be modelled to map a hierarchy of its vital components such as maintenance informatics media. Furthermore it explains the interaction between the components of maintenance informatics such as planning, evidence and control with actual performance of maintenance actions such as repair operations, store up keeping and shutdown maintenance. The selected knowledge, collated from variety of publications1-29, has been summarised to provide a multidisciplinary discourse, outlining why the Maintenance Management needs informatics components such as planning, control and documentation
Maintenance Shop Organization Since the basic functions and tasks of a mainte- nance shop are the same, its organization is fairly standard regardless of shop size or authorized echelon of maintenance. The difference among shops is mainly the workload associated with each function or task and the resources required. This appendix addresses establishment of a basic main- tenance shop applicable to a wide range of scenarios
Maintenance, a Business Centred Approach
Maintenance: Can Your Mill Produce the Right Results? A summary of trends and opportunities in Reliability and Maintenance
Making “Acronyms” Work As in any point in time, we are surrounded by new initiatives represented by some new acronym. We are faced with decisions as to how to improve our respective situations with all of these technologies available. Which are fads and which have substance? Which progress our situations and which merely maintain them? If I apply them, will they work in my facility as at others? We will explore the rationalization and reasoning behind such concerns in this article
Making Maintenance a priority in your organisation
Managing Maintenance as a Business Starting from the viewpoint that Maintenance is a Business (in fact a service business), this article outlines the key elements involved in successfully managing that business, including Determining a Maintenance Philosophy, Defining a Mission and Objectives, Organizing the Business, and Measuring Business Performance. It suggests some strategies for success, and how a CMMS may assist in achieving this success. - requires free Adobe Acrobat Reader for viewing.
Mastering the Maintenance Process The basics that you must master and some simple rules to follow to keep your course toward progress steady and the focus of your personnel on maintenance and its effect on reliability - [WARNING - large 2.2 Mb pdf file] - requires free Adobe Acrobat Reader for viewing.
Maximizing Machinery Reliability - the team approach This paper explores the common pitfalls and barriers to implementing real improvements in machinery reliability and plant / maintenance performance and presents practical real world procedures and processes for improving machinery reliability. - requires free Adobe Acrobat Reader for viewing.
Measuring the Effectiveness of Lean Thinking Activities within Maintenance This paper discusses the combined issues of lean thinking, maintenance, and measures of performance to identify the impact of lean thinking within maintenance - requires free Adobe Acrobat Reader for viewing.
Mixing the Best of Modern Methods Nobody would deny that RCM, RBI, 6 Sigma, TPM, TQM, and many other solutions potentially provide benefits to most organizations. This paper, from John Woodhouse of the Woodhouse Partnership discusses how to integrate these 'solutions' into a sustainable 'home-owned' suite of best practices. - requires free Adobe Acrobat Reader for viewing.
Morning meetings Most morning meetings are not very effective or meaningful to the attendees
Moving from a Repair-focused to a Reliability-focused Culture Discusses the five key elements required to successfully transition from a traditional, repair-focused organisational culture, to a proactive, reliability-focused culture, and reap the rewards of increased performance of both equipment and people - requires free Adobe Acrobat Reader for viewing.
Moving to World Class Maintenance - It's Like Driving Your Car
NASA Procedures and Guidelines - Facilities Maintenance Management The methodology NASA has published on how it has developed its facilities maintence strategy
Not Enough People - Dedicate Maintenance Engineers This is the ninth follow-up article to the July 2004 article, Not Enough People. Remember our discussion on the laws of physics - we know that a body at rest tends to stay at rest and a body in motion tends to stay in motion unless acted upon by an outside force. Change Management is similar. - requires free Adobe Acrobat Reader for viewing.
Novozymes Leverages Results Oriented Maintenance TM and Highly Motivated Staff to Win the North American Maintenance Excellence (NAME) Award 2000 Novozymes North America, Franklinton , North Carolina , a company with Scandinavian roots and management style won the coveted North American Maintenance Excellence Award (NAME) 2000
Operations + Maintenance = Production The vital relationship between operations, maintenance, and engineering
Operations + Maintenance = Production (part 2) The vital relationship between operations, maintenance, and engineering
Operations + Maintenance = Production (part 3) The vital relationship between operations, maintenance, and engineering
Operations + Maintenance = Production (part 4) The vital relationship between operations, maintenance, and engineering
Operations + Maintenance = Production (part 5) The vital relationship between operations, maintenance, and engineering
Operator Maintenance - Key to reducing breakdowns It is said, "Accidents do not happen, they are caused". The same is true for equipment breakdowns. They are due to human reasons - negligence, ignorance, attitude, etc. There is always a human factor behind any equipment failure. Since breakdowns are caused and do not happen on their own, they are preventable. Failure investigation may point to various reasons for failures (Table 1) but the root cause of all failures is human
Organizational Focusing - A Renaissance Of Profitability courtesy of Reliability Center, Inc.
Path Forward to a Profit-Centered Maintenance Operation - requires free Adobe Acrobat Reader for viewing.
Planning and Conduct of Operational Readiness Reviews (ORR) US Department of Energy standard for the planning and conduct of Operational Readiness Reviews
Plant Maintenance Strategy: Key For Enhancing Profitability Proper maintenance of plant equipment can significantly reduce the overall operating cost, while boosting the productivity of the plant. Although many management personnel often view plant maintenance as an expense, a more positive approach in looking at it is to view maintenance works as a profit center. The key to this approach lies in a new perspective of proactive maintenance approach.
Powered By Rx - Part 3 The second foundation element of ‘Powered by Reliability Excellence’ is a proactive culture in which Operations owns reliability and functions in a true partnership with the Maintenance function to generate the most value from the physical assets. - requires free Adobe Acrobat Reader for viewing.
Principles of the Transformation of the Maintenance Function to World-Class Standards of Performance What can you do, as Plant Engineer / Engineering Manager, to improve the effectiveness of the maintenance function in your organisation?
Proactive Maintenance as a Strategic Business Advantage - requires free Adobe Acrobat Reader for viewing.
Proactive Manufacturing at BPs Lima Oil Refinery - requires free Adobe Acrobat Reader for viewing.
Procedure Based Maintenance This paper introduces a compelling argument for development of and adherence to procedure based maintenance when implementing and executing a modern program to ensure maximum capacity of a plant and reliability of its equipment. The argument is based on a new analysis of four (4) statistically significant failure profile distribution studies over the period of the last 40 years, the latest of which was completed in 2001. - requires free Adobe Acrobat Reader for viewing.
Process Reliability and Six Sigma
Profit Optimization and How to Validate Results With Your Maintenance Excellence Index - requires free Adobe Acrobat Reader for viewing.
Project Optimization of Plant Stoppages
Providing Productive Capacity Maintenance alone cannot provide productive capacity and ensure reliability. Production alone cannot provide productive capacity and ensure reliability. - requires free Adobe Acrobat Reader for viewing.
Quality Assured Maintenance Management For Coal Handling Plant Developing Quality Assured Maintenance Management (QAMM) for CHP is very important for improving quality and reducing operating costs. This type of maintenance policy and strategy will improve performance of Coal Handling Plants through availability of equipment, reduction in railway costs through demurrage and further supplying constant flow of fuel to boiler to avoid failure of energy supply to consumers. - requires free Adobe Acrobat Reader for viewing.
Reasons to Replace Equipment Determining when a piece of equipment has reached the end of its useful life cycle in the company's overall reliability strategy can often be difficult if not looked at in the proper perspective.
Reasons to Replace Equipment Determining when a piece of equipment has reached the end of its useful life cycle in the company’s overall reliability strategy can often be difficult if not looked at in the proper perspective
Re-inventing the Maintenance Process - Towards Zero Downtime
Reliability and Accountability The recent electricity outage in North America brought Reliability issues to the surface, this time not only for engineers but also for politicians. The solution to the problem, according to North American Electric Reliability Council (NERC) is reliability enforcement through legislation. According to NERC, “reliability rules must be made mandatory and enforceable” and “legislative action is needed to maintain Electric System Reliability”. How do we achieve this aim? - requires free Adobe Acrobat Reader for viewing.
Reliability and Maintenance Management Current Best Practices (part 2) A discussion on comparing maintenance cost with ERV
Reliability and Maintenance Management Current Best Practices part 1 A discussion on comparing maintenance cost with ERV
Reliability as a Strategic Initiative Reliability is recognized to be a critical element in manufacturing performance and market competitiveness, (maybe even survival) in today's manufacturing environment. le: Manufacturing plants have applied an alphabet soup of improvement methods to achieve improvement: WCM, JIT, TQM, CIM, Lean, Six Sigma, and others, at the cost of millions of dollars - everything but maintenance and reliability! - requires free Adobe Acrobat Reader for viewing.
Reliability Concepts - Precision Based Reliability How can we achieve a failure free environment? The answer is really quite simple. All that is required is the strategic use of our experience, talents and technologies to continuously improve our facilities.
Reliability Goes Nonfat With Lean Maintenance The move from a reactive to a proactive maintenance strategy (RCM, TPM, etc.) is made easier when a preliminary focus is applied to eliminating waste in the maintenance delivery and management system
Reliability Goes Nonfat With Lean Maintenance
Reliability Improvements Drive Down Maintenance Costs An organization must focus on sustainable results, not just cutting costs. Three case studies illustrate.
Reliability Improvements Drive Down Maintenance Costs An organization must focus on sustainable results, not just cutting costs. Three case studies illustrate
Reliability: Past, Present and Future This article, part of the Reliability Handbook, originally published by PEM magazine in Canada, outlines some thoughts on the development of Reliability Management - requires free Adobe Acrobat Reader for viewing.
Reminiscences of the Evolution of Reliability in Manufacturing
Repair vs Replace - Key Principles
Safety and Reactive Maintenance It makes sense that there is a strong correlation between safety incidents, injuries and reactive maintenance. In a reactive situation you might not take the time you should to plan and think before you take action. The urgency also call out the so common hero in maintenance crafts people and they take risks they should not take.
Setting disciplined priorities When prioritizing maintenance work, one must consider its importance to the entire company in question
Sharing Engineering Information - requires free Adobe Acrobat Reader for viewing.
Sludge - Avoiding Mismanagement of Warranty and Insurance Claims A CMMS worth its salt should treat Warranty & Policy Claims Receivable as just that, monies owed to your organization. The system should provide conventions for recording Warranty & Policy Claims directly from a maintenance work order to Warranty & Policy Claims Receivable, and/or generating a debit memo to Accounts Payable, to the vendor’s account. - requires free Adobe Acrobat Reader for viewing.
Smart methods Some of the most common methods that can be used in preventive and corrective maintenance
Smart methods (Part 2) Some of the most common methods that can be used in preventive and corrective maintenance
Smart methods (Part 3) Some of the most common methods that can be used in preventive and corrective maintenance
Smurfit-Stone Pursues Profitable Path with Fernandina Maintenance Program significant efforts have been made to improve the overall performance of Smurfit-Stone’s mill at Fernandina Beach, in particular by addressing maintenance operations, maintenance cost, and equipment reliability.
Solution Oriented Asset Reliability - requires free Adobe Acrobat Reader for viewing.
Stalking Maintenance quality Quality control is hard to define in maintenance. Everyone knows when its missing but its hard to tell when its there.
Stocks and Spares Through the Internet There's nothing new in getting spare parts from a friend. Now the Internet can assist in this process
Supervisors & their Key Link to Productivity Supervision is the first essential level of management in any organization. The supervisor’s role is to encourage members of a work unit to contribute positively toward accomplishing the organization’s goals and objectives. If you have ever attempted to introduce change or continuous improvement in your plant without the universal support of your first-line supervisors, you will understand the critical nature of this function. As the most visible level of management in any plant, front-line supervisors play a pivotal role in both existing plant performance and any attempt at change.
Survey Results - Design for Maintainability Results of the 1999 Plant Maintenance Resource Center survey on Design for Maintainability and Reliability
Surviving Changes in Management
Symbiosis of Maintenance and Safety in process industry This article highlights the mutual relationship between maintenance and safety. Process industry is generally based on the cascading effect of various unit operations. In order to maintain these operations proactive maintenance practices should be adopted. Planned Maintenance and Autonomous maintenance should be adopted and integrated with safety aspects.
Synergetic Asset Management A innovation in implementation of asset management practices as a source of additional profitability Businesses in the manufacturing, process or infrastructure industries have a large capital investment in the physical assets used in their operation.
Take Stock of your Maintenance Storeroom From New Standard Institute
Take Stock of Your Operation This article is part of the Reliability Handbook, originally published by PEM magazine in Canada. - requires free Adobe Acrobat Reader for viewing.
The Accuracy Controlled Enterprise Highly reliable equipment is necessary to reduce production costs and maximize production throughput. High reliability from operating equipment requires high quality reassembly, coupled with the correct operating practices. You can guarantee correct maintenance and proper plant operation by specifying a target and tolerance in maintenance and operating procedures. Having a target and tolerance sets the recognized acceptance criterion. - requires free Adobe Acrobat Reader for viewing.
The Battle of Maintenance
The battle of maintenance, maintenance is war!
The business of networking people and information together Proves and highlights the advantage of belonging to an organization
The Coming Maintenance Crisis During the past five years I have discovered an alarming trend concerning maintenance and industry's ability to provide safe, economic equipment and vehicles to operate
The Cost of Maintenance Can Send Your Business Broke The smart business owner buys equipment that needs little maintenance and insures that the business’ design, maintenance, operating and procurement policies and practices all work toward having long-running, long-lived, never-failing plant. - requires free Adobe Acrobat Reader for viewing.
The Disastrous Effects of Deferring Maintenance When we attempt to force maintenance spending into specific lumps of time that do not meet the needs of our machines, we create the need to defer maintenance. Maintenance budgets fail because final budgeting authorities do not understand the disastrous consequences of deferring maintenance
The Disastrous Effects Of Deferring School District Maintenance Our education system in Texas is under sever budget stress and we are examining options that cut funding for schoolhouse maintenance. The need to cut ISD spending is absolutely necessary. However, across the board cuts in departmental budgets can create a financial disaster when applied to the funding for the maintenance of ISD physical assets
The Discipline of Maintenance Excellence Maintenance personnel, planners, and maintenance and operations managers, with no training on their roles and responsibilities, can be confused about the overall objective of Maintenance Excellence. This article describes the elements of discipline must be put in place when heading down the road to maintenance excellence
The End of the Beginning Commissioning is the time when you first see the conceptual plant in its physical form and when you realise what you have got, what you haven’t got and understand the gap between what you wanted and what you will live with. It is the moment of truth, a time of good news and bad news but also a time when through good management we can still have an influence on the ongoing asset life cycle. - requires free Adobe Acrobat Reader for viewing.
The Evolution of Reliability This article is part of the Reliability Handbook, originally published by PEM magazine in Canada. - requires free Adobe Acrobat Reader for viewing.
The Failure Dilemma: How To Move Towards Proaction When Working In a Reactive Environment
The Fate of Proaction When Economic Downturn Occurs When money is tightened in today’s industry, how does it affect decision-making? Do companies expense proaction for reaction? Are ethics compromised?
The Fourth Generation of Maintenance This paper, from Sandy Dunn of Assetivity, the webmaster of the Plant Maintenance Resource Center discusses the major issues that may shape the nature of the fourth generation of maintenance, and argues that the fourth generation of maintenance will focus on failure elimination, rather than prediction or prevention. This will involve two major improvement thrusts - the first involves an expansion of the technical focus of maintenance managers and professionals in areas such as equipment selection and design, and the second involves failure elimination through the more effective application of organisational, systemic, and cultural controls requiring greater understanding and appreciation of the soft skills. - requires free Adobe Acrobat Reader for viewing.
The Future of Asset Managemen This article explores a broad vision for asset management and brands this vision Strategic Asset Management (SAM). SAM is an integrated set of processes that systematically derive the highest value from plant assets, through a consistent philosophy, plans and objectives, and cooperative involvement by everyone in the plant. - requires free Adobe Acrobat Reader for viewing.
The Health and Safety System in Great Britain This guide, published by the British Health and Safety Executive (HSE) outlines the health and safety system in Great Britain. It is aimed at responding to queries received from overseas, but many Britons will find this publication useful also. - requires free Adobe Acrobat Reader for viewing.
The Holy Grail of Maintenance PM is the best approach, right? After 5000 years of Preventive Maintenance (they used to do PM inspections on the great pyramids) why is the PM approach not the dominant one? Why do we still need to argue for resources? Why do over 70% of all organizations with physical assets only have a rudimentary PM system or none at all?
The Maintenance Management Guide An overview of Maintenance Management in a Powerpoint Presentation (available by purchase only)
The Maintenance Theory Jungle
The Multi-Skill Effort From New Standard Institute
The Mystery of the Lean Toolbox Many of today’s Lean Manufacturing teachers, consultants, workshops, publications, and initiatives describe a Lean Toolbox. This toolbox contains the various improvement tools that have become part of the Lean Manufacturing initiative. Robert M. Williamson, president of Strategic Work Systems describes what is in these lean toolboxes
The Mystery of the Lean Toolbox Many of today’s Lean Manufacturing initiatives describe a Lean Toolbox. There appears to be a whole box full of new tools to help us achieve “Lean.” But most of these tools are not new, and there are some basic tools missing.
The Pioneering of Reliability into the 21st Century
The Real Loss Occurs After the Fire is Extinguished The difference between a “minor disruption” and a “catastrophe” is often times determined by the assessments and decisions (or lack of) made within the first 48 hours following a fire incident. Understanding the vulnerability of facilities and equipment assets exposed to the perils of fire and the resources to combat them, is often overlooked during the critical stages of the recovery effort. One thing is certain, the first 48 hours are critical and irreplaceable. The purpose of this article is to provide a general guide to uncovering the unique hazards of equipment damage due to fire and then maximizing the recovery efforts of those assets.
The Role of Human Factors in Improving Aviation Safety Human error has been documented as a primary contributor to more than 70% of commercial airplane hull-loss accidents.
The Role of Maintenance Management Consultants
The SAMI Asset Healthcare Triangle Series: Stage 1 This is a compilation of 12 articles written by Dave Army of Strategic Asset Management Inc. (SAMI) outlining the components of Stage 1 of the SAMI Asset Heathcare triangle. It covers Identification of Work, Work Prioritization, Long Range Scheduling, Look Ahead Scheduling, Materials Management, Preventive Maintenance, Planners, The Work Plan, Work Execution, Work Closure, CMMS and Metrics
The Tale of an Old Clock and Reliability A broken clock is right exactly twice each day. But did you ever think about what "right" really means?
The True Cost of Downtime
The True Cost of Maintenance One of the largest controllable manufacturing costs is in maintenance operations. But what is the true cost of our maintenance systems? - requires free Adobe Acrobat Reader for viewing.
The use of Information Systems in Fault Diagnosis This paper describes research that has been undertaken to investigate the effectiveness of maintenance information systems to support activities during machine breakdown. - requires free Adobe Acrobat Reader for viewing.
Think like a Number Cruncher - requires free Adobe Acrobat Reader for viewing.
Three Waves to Reliability Excellence In this methodology, operations own reliability, and maintenance is an equal partner dedicated to providing timely and effective methods, skills, expertise, and support. - requires free Adobe Acrobat Reader for viewing.
TIM, 13 steps to World Class Maintenance
Tough Choices The figures in this article describe an actual case where a pulp mill decided to do whatever it took to cut costs - mainly through maintenance cutbacks, with disastrous results.
Turnaround Project Management Primer This handbook was prepared to help those whose responsibilities include the management of process plant turnarounds
Visible and Invisible Maintenance Cost Savings Most organizations take a short term approach to cost reduction and savings which in the long term will be very costly.
Web-Based Government Maintenance Information For The People The U.S. government has embraced the web and made it easy to find documents relating to maintenance and reliability or any other subject you care to research.
What comes first? What do we improve first? Do we start with Root Cause Problem Elimination (RCPE) or do we start with Preventive Maintenance and Planning and Scheduling?
What Constitutes world-class reliability and maintenance? How can you tell if an organization is world-class or not?
What Constitutes World-Class Reliability and Maintenance? (part 2) In this column, I continue discussing the systems and practices that indicate to me that a mill is "world-class."
What Constitutes World-Class Reliability and Maintenance? (part 3) In this column, I continue discussing the systems and practices that indicate to me that a mill is "world-class."
What Constitutes World-Class Reliability and Maintenance? (part 4) In this column, I continue discussing the systems and practices that indicate to me that a mill is "world-class."
What Constitutes World-Class Reliability and Maintenance? (part 5) In this column, I continue discussing the systems and practices that indicate to me that a mill is "world-class."
What Constitutes World-Class Reliability and Maintenance? (part 6) In this column, I continue discussing the systems and practices that indicate to me that a mill is "world-class."
What do bosses really want from the maintenance effort? We don't have to be mind readers about what the big bosses want from maintenance. We just have to read the Wall Street Journal or any newspaper business section
What is Lean Maintenance? Much has been written about lean manufacturing and the lean enterprise—enough that nearly all readers are familiar with the concepts as well as the phrases themselves. But what about lean maintenance? - requires free Adobe Acrobat Reader for viewing.
What is the Cost of Unreliability? By expending effort "up front" you save many times more money in future years.
What shutdowns, why and when? planned shutdowns are still an enigma for many organisations. Much effort has gone into the efficient planning and delivery of the work involved, but relatively little guidance exists for determining what work is worth doing in the first place, and how this should be clustered into appropriate packages to share shutdown opportunities. - requires free Adobe Acrobat Reader for viewing.
What Sustains a Partnership? Your plant is probably like most, Operations is accountable for OEE and Maintenance is responsible for Maintenance Cost and is focused on the Uptime or Availability portion of OEE. Typically, Maintenance needs more money and more downtime to fix things and operations is pressured to produce more volume at lower cost. Therefore, the stage is set, Operations wants improvements and maintenance is holding the checkbook and may need more downtime. Is this anyway to build a partnership? - requires free Adobe Acrobat Reader for viewing.
What the Internet Isn't In America, if something is important, it is often mistaken for having an extraordinary economic value
When You're the Establishment It was easy to whine and complain about prejudice and injustice when we were the impatient youngsters trying to survive in this profession. But what are your responsibilities to the impatient and embattled plant engineering youngsters of today, now that you are the establishment? - requires free Adobe Acrobat Reader for viewing.
When You're the Establishment II What mismanagement of Plant Maintenance certificates, certification and licensing programs has cost this profession. Why corporations don’t demand Maintenance certification when hiring. Why the entire plant maintenance profession could be gone in 7-8 years! How this crisis should be turned around, organized, administered, and managed for future growth. - requires free Adobe Acrobat Reader for viewing.
Who Needs an Asset Performance Improvement Strategy? Asset performance is the efficiency by which a company converts its investment in plant, equipment and inventories, into sales and profits. In today’s rapidly changing business climate, challenged by global competition, reaching the maximum level of asset performance is essential and should be among a company’s strategic objectives. Therefore, Asset Performance Improvement initiatives are vital to enhancing or maintaining a company’s competitive position. However, the data shows that the majority of operational improvement initiatives fall short of expectations
Why Asset Life Management? Asset Life Management, is a continuous strategic asset planning process used to develop management strategies that will: Identify the best asset performance required to achieve future operations targets and corporate plans, Ensure ongoing compatibility between the asset and the changing operations environment. - requires free Adobe Acrobat Reader for viewing.
Why many maintenance improvement initiatives fail to deliver expected results I. - Hedgehog or Fox? It is not uncommon that many reliability and maintenance improvement initiatives fail to deliver expected results. Why is it so?
Why Planned Maintenance Isn’t Enough Anymore A Comparison of Success at DuPont vs. BP Lima by Winston P. Ledet, Ledet Enterprises & Paul A. Monus , BP
Why Six Sigma and Other Scientific Methods Cannot Predict Nonlinear Operations & Maintenance Costs This white paper is offered to explore why programs such as Six Sigma are not the complete solution to managerial challenges in organizational environments that have a heavy investment in mechanical assets and facilities that require efficient maintenance to assure continuity of service
Workplace Hazard Assessment It is the responsibility of employers to determine any hazards that exist or may exist in their respective workplaces or jobsites. What is a hazard? A hazard is defined as a potential source of harm. What are employers required to do per OSHA requirements?
World Class Maintenance at Anheuser-Busch With initiatives and support from top management and scheduled execution by technical process support, Anheuser-Busch (A-B) has achieved world class maintenance. Keeping maintenance at this level requires 24/7 vigilance and dedication at both Corporate and Plant levels. This article examines some of the processes A-B uses to sustain the high quality of its maintenance
World Class Maintenance Strategy Design Techniques This article covers two major techniques for designing World-Class maintenance strategies. The advantages and disadvantages of each technique are briefly discussed and a framework combining both techniques is recommended
World-Class Simplicity...from the 14th Century Our manufacturing world can be unnecessarily complicated. Complex solutions are often developed to address relatively simple problems. Now is the time to seek world-class simplicity...a principle taught by a 14th century monk.
Writing Effective Maintenance And Reliability Mission Statements Many may think a mission statement requires a document the size of War and Peace (Tolstoy, Viking Press, ISBN 0140444173); however, before you begin writing the next chapter, check what some of the experts advise by visiting the following online resources
You Cannot Do What You Cannot Imagine - Introducing Precision
Your Maintenance Costs are too High I am quite sure that every maintenance manager has heard this statement many times during his career. This paper from Herman Ellis of Qualitech Management Services explores some eight key principles behind this statement. - requires free Adobe Acrobat Reader for viewing.


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