Build a System for World Class Asset Reliability and Lasting Operational Excellence Performance

Plant Wellness Way: a life cycle system-of-reliability methodology that delivers outstanding equipment reliability in industrial operations

The Plant Wellness Way is a sure path to world class reliability needed for Operational Excellence. Engineer your asset life cycles with the six IONICS processes and design-in maximum operating profits from your operation forevermore.

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Hello and welcome,

There is sure way to get world class plant and equipment reliability and Operational Excellence performance into your company.

The Plant Wellness Way changes your business to do those things that produce Operational Excellence. You design and lock the right practices into your business DNA and so you maximise your operating profits forevermore. Because you do the right things rightly; you must also get the right results.

Read on and learn about the simple, powerful Plant and Equipment Wellness Way lifecycle system-of-reliability.

The Plant Wellness Way Enterprise Asset Management Methodology Works because You Focus on the Important

The Plant Wellness Way delivers rapid operational performance improvement by focusing your energy and efforts on doing the right things that bring sure operational success. You build truly effective business processes and put best practices into your operation so that it is sure to deliver guaranteed world class operational performance.

The Plant and Equipment Wellness Way enterprise asset management methodology makes all previous enterprise asset management methodologies obsolete.

The vital difference between other enterprise asset management methods and the Plant Wellness Way, is that PWW tells you HOW to get outstanding plant and equipment reliability so that you are sure to reach operational excellence performance.

The problem with all previous enterprise asset management methodologies is that they do not tell you how to surely create reliability. They tell you too generally what asset management processes to establish, but none of them explain how exactly to guarantee outstanding equipment reliability and world class plant availability. The Plant Wellness Way (PWW) gives you the answers that all prior asset management and maintenance management methodologies could not do—you get the what and the how of world class operational performance!

The Plant Wellness Way is a systematic physical asset management methodology that provides a sure operational excellence solution and world class reliability results for every company that uses it. Plant Wellness lets you identify and design exactly what is the simplest and most certain way for you to have world class asset management performance in your company; no matter who you are or what industry you are in.

For world class operational excellence you need the right combination of tools, techniques and methods that gets your people and business focused on doing the important things that deliver highly reliable operational assets. When you have the wrong focus you do many things that are of little value in achieving the operational excellence you want. Everyone in the organisation is busy, but because they are doing what is unmportant for enterprise asset management success, you miss out on operational excellence performance.

By using the PWW Physics of Failure based enterprise asset management and maintenance management method, you discover exactly how to make world-class operational performance happen for your company. Because PWW is based on reliability first principles you are sure to arrive at the right, vital changes you need to make to reach operational and maintenance excellence.

The 'Stress-to-Process' engineering asset management model below explains the business processes that you need to put in place to produce world-class maintenance and reliability results. With this scientifically-based model you can design and build the least cost, least manpower and smallest enterprise asset management systems and processes that produce sure operational excellence.

To create world-class reliability and maintenance success in your operation there are three things you need to do:

• Prevent stress, fatigue and contamination of your equipment parts — your machines only stop when their parts fail. The health of your equipment parts fatally impacts any chance you have for operational excellence.
• Control work quality and task accuracy throughout the engineering asset management life-cycle to protect against 'human factors’ and human error in industry. Mistakes, misunderstanding and ignorance by people during design, manufacture, selection, storage, installation, operation, and maintenance cause 70 to 80 percent of your plant availability and reliability problems.
• Build lean, life-cycle asset management processes full of defect elimination and zero breakdown strategies. A successful life-cycle asset management system naturally produces the first two requirements.

The 'Stress to Process' asset reliability model lets you build an engineering asset management system to deliver the low stresses your machines need for a long, failure-free life. With the right business processes you can surely bring operational excellence and world-class asset maintenance and reliability results to your business.

With Plant and Equipment Wellness you select the correct life cycle practices, apply the important Lean tools and the use vital ACE 3T quality assurance to produce outstanding and lasting plant and equipment reliability. You get powerful people management tools and quality assurance techniques that make sure the right ways are always practiced in your company. (Buy the Plant and Equipment Wellness book at the Engineers Australia Media website, and read it to get an overview of the changes that you need to make in your operation.)

The ways and methods for successful, lasting life cycle enterprise asset management are what you get when you follow the Plant and Equipment Wellness Way. When you adopt the Plant Wellness Way your company cannot stay the same—within three years it can have world class operational performance.

What is Plant Wellness Way to Asset Management Success?

Plant and Equipment Wellness is an enterprise asset management methodology based on Physics of Failure science. You work from a part's material atomic structure properties up to the correct business processes needed to sustain outstanding equipment reliability. This approach makes it a universal process that can be used in every company to create and sustain trouble-free, highly-reliable operating equipment to help them reach world class operational excellence. You can read this short overview of the Plant Wellness Way methodology.

The Plant Wellness Way is the next generation of asset management methodology. It uses new analytical tools, new software solutions, new measurements for operational success and new life cycle strategies that keep your machines and equipment healthy all their operating lifetime.

With Plant Wellness you do not maintain and repair your equipment, but instead you create the right conditions for your operating plant and machines to stay well all life long. You produce lasting health by providing the causes of high equipment reliability. You instigate and sustain the necessary longevity requirements and practices in your operation so plant and equipment wellness always results.

When you have a physical asset management methodology with the word Wellness in its title you have to look at maintenance in a totally different light. If you have to repair your equipment then in terms of Plant Wellness your processes to deliver equipment health and well-being have failed. Your machines are not at all well if you have to fix them.

The great power of the Plant Wellness Way is its simple approach—one methodology to create exceptional equipment reliability that works for every operation. The same process is used everywhere and adapts to each operation's circumstances. The successful maintenance and reliability practices that cause your equipment to be healthy are designed into your business practices. World class reliability performance is locked into place in your business habits and culture forever.

Plant Wellness lets you introduce and sustain the proper business-wide discipline you need to quickly improve your plant and equipment maintenance performance, lower your maintenance costs, lift your plant uptime and create new operational profits because your equipment always performs reliably.

Use the Plant Wellness Way to identify exactly what to do to make your equipment healthy. You can now improve your asset maintenance and plant operating processes and practices so that you always get the world-class operational asset performance that drives operational excellence.

The Plant Wellness Elements

World class equipment performance needs the right reliability improvement practices in your operation at each stage of your plant and equipment's life-cycle. That's what the Plant Wellness methodology does. It gives your business the methodology and structure to build the culture, systems, processes and practices that create the world-class equipment reliability you need for low cost production with low cost maintenance. You create reliability and maintenance excellence that rapidly takes your business to world-class maintenance management and operational performance. With world-class processes, practices and behaviour you cannot help but get world-class productivity from highly reliable plant and equipment that have the lowest maintenance costs.

With Plant and Equipment Wellness You Design a Straight Pathway to Sure Maintenance and Reliability Excellence

Plant Wellness instils best-practice maintenance and reliability excellence throughout the life cycle. It works for every operation and organisation. Your operational success is achieved because the methods and practices of world-class maintenance and world-class reliability are imbedded and used in your operation by design. The figure below shows what happens in your company when Plant and Equipment Wellness releases the greatest operating performance and operating profit that can be achieved from your business.

The Plant Wellness Way is Designed to Bring You Low Maintenance Costs by Creating High Reliability Assets

Human Wellness is a state of complete physical, mental, and social well-being that is disease-free. It encourages an integrated and dynamic level of performance. It is dependent on self-responsibility and focuses on maximizing ones potential.

Plant Wellness is a systematic method for generating maximum operating profit (maximising potential) through failure elimination (disease-free), risk management and proactive maintenance (seeking complete well-being), Lean waste removal (integrated and dynamic performance) and work quality assurance (self-responsibility).

Plant Wellness is a perfect metaphor for industrial maintenance and asset management success. When you put the right maintenance processes and reliability practices into your maintenance and reliability system you will fix your reliability and maintenance problems. You will stop your production problems with business processes and maintenance practices that remove the defects which cause your plant and equipment failures.

Plant Wellness gets rapid reliability improvement and low maintenance costs because it makes you apply what we call 'Series System Reliability Improvement Property No. 3' in your business. It makes you create a best-practice maintenance and reliability culture across your operation that leads to quick reliability growth and a rapid fall in maintenance costs seemingly overnight.

There is a lot of money to be made from reliability and maintenance excellence. The return is around ten to one—for every dollar you save in equipment failures you make an extra ten in operating profit. Those big, new profits make a very powerful business case for bringing high reliability to your organization. (This article explains how to calculate your Instantaneous Cost of Failure.)

Plant Wellness Way Asset Management Model

You can certainly have best-practice maintenance and world-class reliability results from your business. You need only select the right blend of best-practice engineering asset management, combined with efficient, lean process improvements, and then lock them in-place with a truly effective work quality assurance system. New profits from your operation will pour into your bank with your new world-class competitive maintenance and reliability system.

The unique Plant and Equipment Wellness Methodology uses the 6-step IONICS process to control the five important issues in successful engineering asset management - variability in outcomes, prevention of failure, life-cycle risk control, work quality assurance and process step value contribution. IONICS simply means to Identify risks, Order by importance, Numerate options, Introduce solutions, Control processes and Synthesize better ways.

Plant and Equipment Wellness uses the six systemic IONICS steps to deliver a lifetime of outstanding reliability and maintenance management success. It has just one focus—to build the smallest and fewest life-cycle asset management and maintenance management solutions that always deliver best practice maintenance and reliability excellence TO your equipment.

When you implement the defect elimination requirements, risk reduction processes and reliability growth methodologies of Plant and Equipment Wellness, you:

• guarantee use of best practice maintenance and contractor work quality assurance
• reduce maintenance costs in your operation by creating failure-free equipment,
• deliver outstanding precision operation of all production plant and machinery,
• encourage management and employees to create world class reliability solutions,
• make your operation a highly reliable organization that its people vigorously support,
• build superior business processes that deliver failure prevention,
• drive the 'chance risk reduction' mindset of a high reliability organization,
• produce top quality product with failure-free, reliable equipment.

Plant and Equipment Wellness: Your Sure Way to World Class Maintenance, Reliability and Operational Excellence

You will be wonderfully surprised at how simple it is to create your own industrial asset management success when your maintenance and reliability system forever eliminates your plant and equipment reliability problems. This is inevitable when you create life-cycle maintenance and reliability systems and processes that produce best practice maintenance performance and maintenance and reliability excellence in your organization. Use Plant Wellness to introduce life-cycle profit asset management, precision operation and precision maintenance quality assurance into your operation that create a best practice reliability and maintenance system.

How the Plant Wellness Way Delivers New
Profits Now Hidden in Your Business.

I will use the image below, showing the business effect of the Enterprise Wellness Way, to explain what the Plant Wellness Way does to an operation to recover lost and wasted operating profits.

Your Company produces products that are meant to be of a set quality, but occasionally there are errors that need to be fixed, or money is wasted on needless quality. If you have too many mistakes, problems and overspends you rapidly lose your operating profit.

The errors, wastes and excesses you see in your business result from your business system design. The late quality guru, W. Edwards Deming saw the problem. He said, "Your business is perfectly designed to deliver the results that you get."

Deming was warning us that all your business, operational and maintenance problems are caused by the design of your company systems and its work processes.

We have known about the problem of designed-in business process waste, errors and loss since the 1920's when Walter A. Shewhart of the Bell Telephone Laboratories developed the first work process control tools. W. Edwards Deming learnt from Shewhart and explained it to Japanese managers and engineers in 1950. The Japanese managers and engineers listened and grew to understand what Deming meant. They became world class quality leaders and created highly profitable companies. Most of the rest of the world did not both to heed Deming's simple message!

The dark, outside distribution curve in the Enterprise Wellness Way image represents the current range of outputs from your operation. Dead centre is optimal quality and cost—only what you need; nothing more and nothing less. To the right is money spent unnecessarily on quality you did not need. Like using a pressure coded welder for welding a pipe support bracket, or using a Licensed Technician to do labouring work—you just spent triple the money that you should have spent! To the left is poor and bad quality—all the scrap and rework you now waste. Any outlier results way out on the sides are complete madness.

What Enterprise Wellness Way does for a Company, and Plant Wellness Way does for its Operation and Maintenance, is drive the existing performance closer and closer to the optimal, so that more and more of your production is ideal. Your operational performance becomes the red distribution curve hugging the Optimal result. Because all your production is now just-right, the moneys that were wasted and lost to problems and excess turn immediately into new operating profits.

The closer you get to Optimal the more operating profit you must make. There are huge 'hidden' fortunes waiting for you to collect!

Using the Plant Wellness Way quickly increases operational profit, slashes maintenance costs, stops work quality problems and gets much more production from your operation. Its secret is in how it gets the correct world class business, operational and reliability processes into your company so that the business is designed to be highly productive and deliver greater operational profits.

Lifetime Reliability Solutions (LRS) Consultants use the Plant Wellness Way asset management methodology to create simple, highly efficient and effective business, operational and maintenance processes that stop your operational problems and make excellent product.

We also show you how to lock that operational success into your business DNA and ensure your new operating triumph is sustained forevermore.

We have developed a robust and comprehensive collection of engineering asset management processes that lets you create a successful engineering asset management solution incorporating world class engineering asset management systems and high reliability processes into your business.

We do that by using a 6-step process—IONICS—to identify your competitive maintenance and reliability excellence opportunities. With it you design the easiest, least cost ways to create maintenance and reliability excellence for your equipment parts. This one methodology finds the right asset management strategies, processes and methods that solve your reliability and maintenance problems. Together we use the Plant Wellness Way to plan exactly how and what to do to move your operation to world-class maintenance and engineering asset management performance; simply, quickly, and for least cost.

You Must License the Plant and Equipment Wellness Methodology

Only licensed consultants and operations can use the Plant Wellness Way. This is to ensure rapid, continuous improvement for its Users. When you take a Plant Wellness Way license you commit to mastering those processes and practices that create outstanding and stunning equipment reliability.

You adopt Plant and Equipment Wellness as the one and only way to do maintenance and reliability in your company. It is a systematic, life cycle focused, enterprise asset management methodology that works for every business. The Plant Wellness Way provides you with one method, one path, to magnificent reliability results forevermore. It is a sure way to lasting operational excellence for those who use it.

Plant Wellness is a proprietary solution and the methodology is available under license to consultants, and to individual operating sites and businesses to use. Follow this link to get details of Plant and Equipment Wellness Licensed Consultant and Site License Information.

The Plant Wellness Manual summarises the business quality system framework you establish to unleash the power of this physical asset health creating and fitness sustaining operational excellence methodology. You can download a PDF version of the Plant Wellness Way Framework Manual.

Examples of selected techniques used in the Plant Wellness Way methodology are available at the Plant Wellness Way Tutorials webpage.

If you want to apply Plant and Equipment Wellness in your operation please ask us and we will provide you with all the information you require. Contact Us today about developing a Plant Wellness maintenance cost reduction and reliability improvement plan that changes your business processes and delivers industrial asset maintenance management and reliability excellence. You will be pleasantly surprised at how simple it is to get best practice maintenance performance and rapid reliability growth so your business can reach Operational Excellence.

My best regards to you,

Mike Sondalini
Managing Director
Lifetime Reliability Solutions HQ