Now, Build Your EAM System to get you operating fortunes

The CEO, Executive, & Manager Who Wants World Class Plant & Equipment Reliability


"Your system is perfectly designed to get the results it gets." This business truth is credited to the late quality guru W. Edwards Deming.

What value and opportunity does this insight bring for you and your company?

Your operating success and profits reflect, and depend totally on, your company's systems and their processes. To get better results, you must change to a system with processes that are totally capable to deliver the performance and outcomes you want.

It's your EAM system, processes, and practices that must be designed to guarantee low production costs, get utmost plant uptime, slash the need for maintenance, and get top productivity from your operating assets. Nothing else you do works!

Using Plant Wellness Way Enterprise Asset Management methodology puts world-class reliability, maintenance, and safety into your operation's systems and processes.

You design and build an “Asset Wellness System” that always delivers utmost reliable plant and equipment, for least maintenance costs, and the biggest operating profits.

Quickly Get World Class Reliable Operating Assets and Your Lowest Maintenance Costs


His operation was in trouble, "We are having many failures in our current systems, both power and water, I am really interested in knowing more about Plant Wellness Way EAM and its maintenance processes."

Here's what we said he and his senior managers could do to most quickly solve their operating assets' reliability problems for least cost.

"Install a Plant Wellness Way EAM system and you will surely stop your plant and equipment breakdowns and turn them into new operating profits. But, by the time you do the training and know how to apply PWW EAM yourself, it will be some 12 months before you are completely comfortable and able in the methodology. It is a long time to live with failure problems and costs that are already too bad.

During that year your organization will lose a fortune due to breakdowns and downtime while you become knowledgeable about PWW EAM. After you get proficient, you still need to apply and teach your team what to do to use PWW EAM. It could easily take another year before your organization starts seeing serious plant and equipment reliability improvements. In that second year the breakdowns, and the resulting financial and production losses, still continue to occur.

Instead, we offer to come to your facility and apply PWW EAM to your operation to make rapid improvements to your operating assets reliability and uptime. The approach we take is to apply PWW EAM fully on a selected number of assets, say 10 percent of the total, and bring them up to full reliability and service.

We will work with you and your team to build the necessary processes and capability within your organization. Once the PWW EAM solutions are completed for the selected assets, then you and your team would apply the methodology to all the rest of your operations. This is the fastest and least cost way to use us to get the plant and equipment reliability and uptime that your organization requires.

Instead of taking two years to see substantial reliability improvement, the first year to do the training and learning, and the second year to teach and implement PWW EAM, you will get improvements and cost reductions within a few months. After the first year you can expect to be well in control of your operating asset reliability, uptime, and maintenance expenses.

To minimise our consultant time and costs, we would resource as much of the work as possible to you and your team. We would work together with your organization to do the project and apply PWW EAM in your operation under our stewardship.

In this way, with our help and support, there will be rapid improvement to your assets’ performance within a few short weeks. By the time 12 months passes, you will have achieved a great improvement in production supply and security. At the end of two years, you can expect the operating assets reliability and productivity to be a great pride for your organization.

If providing direct and rapid PWW EAM consulting assistance to you and your team is a useful approach, then I can give you a formal fixed price quote for our services. Should you want a firm quote from us, I would appreciate if you provide the asset register and engineering details of the plant and equipment you would want PWW EAM Consultant support to improve.

To get a proposal and indicative costing to bring PWW EAM success to your operation, please indicate the asset types at your site to be in the first 10% to use PWW EAM solutions. It is only necessary to have one asset of each type, as you and your people will then replicate PWW EAM to every other asset of its type in your organization."

Download a redacted PDF copy of the Plant Wellness Way EAM Proposal we sent.

Learn all about Plant Wellness Way EAM and what it can do for your site — simply ask an approved consultant. Our office details are noted on the Contact Us webpage.

Mike Sondalini | Lifetime Reliability Solutions | World Class Operating Asset Reliability

Getting Outstanding fleet equipment reliability and maintenance with PWW EAM

Hi Mr. Sondalini,

I have been reading different articles and other information from your website and I think you have a great program.

I would like to incorporate your teachings into my business and would like to know the best way to do this.

I work for a fleet company with over 10,000 fleet assets, and your teaching is based in a production facility. I don't want to invest a great deal of time in a program that will not be beneficial and useful, so what is your recommendation for doing this?



Hello Grant,

Thank you for your nice comments.

The Plant Wellness Way EAM methodology is applicable to any and all machinery and equipment. It is a universal approach that brings benefits to any asset. Because the techniques used are at the component level, the parts can be from a fleet asset—be it equipment, mobile vehicles, train, plane, and one day soon, spaceships—or in fixed plant production equipment. Service duty does not matter, as PWW EAM will still give you the best solutions for utmost reliability of the part and its parent equipment regardless of what an asset is used for.

Because you only apply PWW EAM on each equipment type, there is one great advantage when using PWW EAM on fleet assets compared to production assets. If you have 10,000 prime movers with diesel engines, then PWW EAM is only done for each engine type, and not 10,000 times. Where as in production plants, it typically turns out that you apply PWW EAM many more times than for fleets due to the wide variety of equipment.

When people enquire on using and adopting PWW EAM, I advise them to do the complete PWW EAM solution on one entire asset only. Pick one important asset and use PWW EAM on it from analysis to implementation. Put the solutions into use and let your people and business trial it and prove its value.

Depending on the asset you choose, allow between three and four months for the “proof” project from end to end. Typically, the project requires a team make-up with mechanical, electrical, and instrumentation expertise in it. One of them will be a team lead that will manage and run the entire project. The other specialists come in and out of the project as they are required. For some phases of the project your own people will need to be involved, such as ACE 3T procedure development, and updating of databases and equipment work orders in your CMMS.

I hope the above is sufficient information for your needs at the moment. Let me know if you have any questions and I’ll answer them.

All the very best to you,

Mike Sondalini | LRS Consultants Global

How to get world class operating asset reliability

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Email by a Businessman Who’s Planned how to market his PWW EAM Consultancy

Good Morning Mike,

Just to recap why I started talking to you (about being a Plant Wellness Way EAM Consultant). My entire life has been involved in maintenance. I did my apprenticeship as an aircraft fitter specialising on helicopters. I worked for various mining companies and then for AtlasCopco, and finally for Tamrock, now Sandvik, before starting my own business in 1999. Wherever I have been responsible for the maintenance of equipment we seemed to have less breakdowns, maybe because I was subconsciously applying the principles I had learnt during my time working on helicopters.

When I came to Zambia I was the Product Support and Training Manager for Tamrock. As this point many of the mines were starting to use maintenance planning programs but I found that (even today) the program is only as good as the people using it and with respect to maintenance it is the 'Human Factor' that has the biggest impact on maintenance and therefore the reliability of the equipment. So I started to put together a training program directed specifically at artisans. I found that just because someone is a qualified artisan it does not necessarily mean they are good maintenance artisans. I was working on a holistic approach to maintenance consisting of planning, management and maintenance of equipment. I had developed something in 1995 which I used whilst working for Tamrock and was looking to update this and market it as package. I had done a lot of research when I came across Lifetime Reliability Solutions (LRS). I requested the book and was blown away because it was exactly what I had been looking for. Why reinvent the wheel? So I contacted you.

After our initial discussion, and after looking at virtually everything on your website, I knew this was the right service for us to to market in Zambia. The other way was to continue on my own and develop package that I can market. I decided you were the right choice.

Below was my thinking regarding LRS:

  1. Market LRS to all our existing client base that will benefit from a PWW EAM system.
  2. Discuss with LRS the possibility of them conducting the first consultancy but at the same time use this opportunity to train specific personnel in our company to support and deliver PWW EAM in future consultant assignments.
  3. Once certified, to then do PWW EAM consultancies on our own in Zambia.
  4. My partner in business is a certified ISO lead internal auditor in ISO 9001, 14001 and OSHAS 18001. She has an exceptional skill in identifying processes and developing procedures for those processes.
  5. Because of my background I have a sound understanding of mechanical, hydraulic and electrical maintenance.
  6. Having been delivering industrial services in Zambia since March 1999, we feel we have the necessary client base to effectively market LRS and PWW EAM locally, and maybe other surrounding countries if you do not have any representation.

I have given this a lot of thought and know we can make a success of it, if given the opportunity.

I do trust that you can see the method in my madness.

Kind Regards,



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“We utilised the services of Lifetime Reliability Solutions to do some pump training and were very impressed with the outcomes. They delivered a customised, in house, pump maintenance and pumping system design training course. Mike and his team developed and delivered the three-day training course in conjunction with our maintenance and engineering staff. The course was well structured and presented, and included practical activities and theory components. Mike’s experience and knowledge in this field enabled him to identify and meet our requirements quickly and effectively.”

- Tony Graham | Manager | Murrumbidgee Irrigation | Australia

"I recommend Lifetime Reliability Solutions (LRS) to any company wanting to see effective results in their maintenance processes, and plant and equipment reliability. We have worked with LRS Consultants at Donhad twice over the past two years. As a manufacturer of forged products it is crucial for our business that our production machinery and systems work at peak performance. Mike Sondalini's expertise in maintenance and asset management has proven very valuable to our company and the maintenance system that we run. We first contacted LRS to review our maintenance management processes. Mike's knowledge and perspective allowed us to improve our maintenance strategy and methods. With his advice our plant and equipment reliability has lifted considerably. LRS Consultants attention to detail and experience motivated us to contract them again to undertake multi-site maintenance audits. Thanks to LRS we have seen an improvement in our production output and started to gain control over our maintenance costs."

- Paul Shelley | Managing Director | Donhad Pty Ltd | Australia


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