Plant Wellness Way EAM Puts a System-of-Reliability into Your Company that Gets Lasting World Class Operating Asset Reliability

Plant Wellness Way EAM is a physics-of-failure based, asset life cycle management methodology that delivers outstanding equipment reliability to industrial, manufacturing, and process sites

You use Plant Wellness Way EAM to eliminate the risks that stop you getting the world class plant and equipment reliability you need for Operational Excellence. With PWWEAM you re-engineer your assets’ life cycle processes and design-in maximum operating profits from your business forevermore.

Plant Wellness Way EAM strategy gets you to design and embed the optimal life cycle asset management processes into your company that guarantee least maintenance costs, world class reliable assets, utmost asset utilization, with the best production output.



Hello and welcome,

Every industrial, process, and manufacturing operation can get world class plant and equipment reliability. Reliability is formulaic—simply do what causes world class reliability and you will get world class reliable operating assets.

Plant Wellness Way EAM lets you design and create a life-cycle-long, business-wide Enterprise Asset Management (EAM) system that delivers world class asset reliability.

Your company, and its people, will naturally have outstandingly reliable production plant and equipment because you built an EAM system to deliver that specific result.


The Plant Wellness Way Enterprise Asset Management Methodology Works because You Control Your Equipment Parts Health

The Plant and Equipment Wellness Way delivers rapid plant and equipment reliability improvement by focusing your energy and efforts on doing what brings outstanding reliability to your assets. You build truly effective business processes and put best reliability practices throughout your operation so you are sure to deliver health and wellness to your equipment’s components.

If the parts don’t fail, your machines don’t stop. That’s what you use PWW EAM to do—design and lock the right practices for outstanding plant and equipment reliability into your business DNA. You turn reliability into a powerful competitive advantage that maximizes your operating profits forevermore.


The Plant Wellness Way Enterprise Asset Management Model


The Plant and Equipment Wellness Way enterprise asset management methodology makes all previous enterprise asset management methodologies obsolete. You can learn why by reading the webpage titled, Turn Life Cycle Asset Management on Its Head if You want Operational Excellence.

The vital difference between other enterprise asset management methods and the Plant Wellness Way (PWW) is with PWW you know exactly HOW you will get outstanding plant and equipment reliability. All the other EAM methodologies do not detail how to get the world class asset reliability you need for operational excellence performance.

You can calculate the new, extra operating profits you will make each year from Plant and Equipment Wellness with the information in this PDF white paper titled, The Plant Wellness Way Difference. It’s quite astounding how much more production success you can get in a very short time when you take the Plant Wellness Way.

PWW EAM gives you the answers that all prior asset management and maintenance management methodologies could not—the step-by-step requirements that bring you world class operating asset reliability.

Plant Wellness and Equipment Way Enterprise Asset Management is a systematic physical asset management methodology that provides you sure world class reliability solutions needed for operational excellence results. PWW EAM lets you identify and design into your company’s DNA the simplest and most certain way to get world class asset management performance—no matter who you are, or what industry you are in.

For world class asset reliability you need the right combination of tools, techniques and methods across the asset life cycle and throughout your business. You must focus on doing the important things that deliver highly reliable operational assets. If you have the wrong focus you do many things that are of little value in achieving the plant and equipment reliability you want. Everyone in the organisation is busy, but because they are doing what is unimportant for enterprise asset management success, you miss out on operational excellence performance.

PWW EAM is a true Physics-of-Failure based enterprise asset management and maintenance management methodology. With PWW EAM you discover exactly how to make world-class operational asset performance happen for your company. Since PWW EAM uses only reliability engineering and risk management principles, you are sure to arrive at effective, success-bringing changes to put into your operation.

The ‘Stress-to-Process’ Plant Wellness Way enterprise 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 for operational excellence.


The Plant and Equipment Wellness Way Stress-to-Process Enterprise Asset Management Model


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 ‘Parts Stress to Business 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 life cycle and business processes you can surely bring world-class maintenance and reliability to your plant and equipment.

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 PWW EAM your company cannot stay the same—within three years you can have world class asset reliability. With Plant and Equipment Wellness you select the correct life cycle practices, apply the right methods, and use the work quality assurance that produces outstanding and lasting plant and equipment reliability. You get powerful work management tools and quality control techniques that make sure the right ways are always practiced in your company.


What is Plant and Equipment Wellness Way to Life Cycle Asset Management Success?

Plant and Equipment Wellness Way EAM 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 PDF report introducing the Plant Wellness Way EAM methodology.

The Plant Wellness Way EAM 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 PWW EAM 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, from a PWW EAM perspective, 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 EAM is its simple approach—one methodology to create exceptional equipment reliability that works for every operation. The same PWW EAM methodology is used everywhere and adapts to each operation’s circumstances. PWW EAM arrives at the successful maintenance and reliability practices that cause your equipment to be healthy, and ensure they are designed into your business practices. World class reliability performance is locked into place in your business habits and culture forever.

Plant Wellness Way EAM 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.

By using PWW EAM you will 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 success.

The plant and equipment wellness way EAM elements - people, processes, culture and capitalPlant Wellness Way EAM 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 PWW EAM 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 Way EAM You Design a Straight Pathway to Sure Maintenance and Reliability Excellence

TPWW EAM instills best-practice maintenance and reliability excellence throughout your assets’ 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 embedded 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 and Equipment Wellness Path to Operational Excellence


The Plant and Equipment Wellness Way EAM Gets Low Maintenance Costs by Creating World Class Asset Reliability

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 and Equipment Wellness Way EAM 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 and Equipment 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.

PWW EAM 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.

You make a lot of new operating profits from reliability and maintenance excellence. The return is around ten to one—for every dollar you save doing maintenance because of equipment failures, you make an extra ten dollars in operating profit. Those big, new profits are a very powerful business case for getting high reliability from your organization’s assets. (This PDF white paper explains how to calculate the business-wide fortunes lost from your plant and equipment breakdowns: The Instantaneous Cost of Failure on Your Business.)


Plant Wellness Way EAM Uses the Six-Step IONICS Process to Design and Embed World Class Asset Reliability in Your Company

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 and effects, Order risks by criticality, Negate component risks, Imbed risk controls across the life cycle, Cultivate chance of process success, and Synthesize continual improvements.

Plant and Equipment Wellness Way has just one focus—to build the smallest and most profitable life-cycle asset management and maintenance management system that always delivers 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: A Sure Way to Get the World Class Asset Reliability You Need for 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 world class asset reliability in your organization. Use Plant Wellness and you will introduce high-profit life-cycle asset management, precision operation, and precision maintenance solutions into your operation that naturally create outstanding production asset reliability.


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

The image below shows the business effects on an Enterprise that Adopts the Plant Wellness Way. It explains 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.

Effect on an Enterprise of using the Plant and Equipment Wellness Way EAM to generate new profits

What the “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 teach you and your people to use the Plant and Equipment Wellness Way asset management methodology. In a five day course you learn how to create simple, highly efficient and effective business, operational and maintenance processes that stop your operational problems and make your operating assets world class reliable.

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

You are taught to develop robust and comprehensive life cycle asset management processes that lets you create a successful engineering asset management solution. You learn to incorporate world class engineering asset management systems and high reliability processes into your business.

You follow the 6-step IONICS process to identify your competitive maintenance and reliability excellence opportunities. With PWW EAM, you design the easiest, least cost ways to create maintenance and reliability excellence for your equipment parts. The Plant and Equipment Wellness Way EAM methodology finds theright asset management strategies, processes and methods that solve your reliability and maintenance problems. You learn to 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.


Get the Rights to Use the Plant and Equipment Wellness Way Methodology

Only approved Plant and Equipment Wellness Way Consultants and sites can use Plant Wellness Way EAM. This is to ensure its users get lasting competitive advantage from adopting the Plant Wellness Way. Licensing also means 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 EAM 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 and Equipment Wellness Way EAM 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.

The Plant and Equipment Wellness Way EAM 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 information on the Plant Wellness Way EAM Approved Consultants.

The Plant Wellness Way EAM Manual summaries the business quality system framework you establish to unleash the power of this physical asset management methodology. You can download a PDF version of the Plant Wellness Way EAM Framework.

To apply Plant and Equipment Wellness Way EAM in your operation, please ask us and we will provide you with all the information you require. Contact Us today about developing a PWW EAM maintenance cost reduction and reliability improvement plan. Together we change your business processes and deliver 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.

All the best to you,

Mike Sondalini
Managing Director
Lifetime Reliability Solutions HQ