14 Ways to Keep Maintenance Costs Low in the Plant Wellness Way Business System-of-Reliability

When your site takes on the Plant Wellness Way philosophy and methodology you change what you do to the practices that ensure you always get world class maintenance, reliability and life cycle asset management results.

Adopt Plant Wellness Way as the company’s asset management strategy and you quickly make site improvements in your engineering, operations and maintenance processes. You do maintenance in highly effective ways.

 

1. Buy Machines and Equipment that Don’t Need Maintenance

From the range of equipment you can afford, work with the manufacturers and look in detail at each component’s design choices. Pick the parts for your machinery that will last the longest time between maintenance outages.

2. Rebuild for High Reliability

Only use overhaul service providers, including your own workshops, which have a sure process to refurbish your equipment back to as-good-as-new condition. Such providers have superbly clean workplaces, their work management systems ensure no errors occur, they use skilled, competent technicians, they conduct precision measurements of parts to insure they meet specification, and they rebuild equipment to exacting quality standards without mistakes.

3. Operate Below 90% of Design Duty

Buy the next bigger size model and run it below capacity—let its strength and reliability pay you back a fortune. A 10% reduction in maximum operating load will extend time between failures by up to five times for parts made of ferrous metals.

4. Operate Parts within Their Design Envelope

Every part in a machine is designed to be used within an operating service envelope specified by its designer. Always stay inside the service limits of all the electronic, electrical, mechanical and structural parts in your machines, and they will give you maximum, trouble-free service life.

5. Keep Working Parts at World Class Health Standards

For every working part define the full range of factors that affect its reliability. For each factor research the conditions needed to give maximum failure-free life, and set them as the engineering standards your organization will strive to achieve.

6. Install Equipment to World Class Precision Standards

Distorted equipment structures and frames pre-stress internal components. Even before a machine is used its parts can be heavily loaded from distortion of the body structure. To test for distortion release the hold down bolts and check how far the equipment moves. On a Plant Wellness way site there must be negligible unintended equipment distortion.

7. Remove the Opportunities that Make Parts Fail

A part’s failure is caused by an event that destroys its microstructure. If there is no opportunity for the material-of-construction destroying event to happen then the part cannot fail.

8. Raise the Microstructure Strength of a Part

Use higher strength materials for parts so the microstructure stress limits are far above the maximum operating stresses. High strength parts are more reliable because the microstructure is not easily damaged by operating overloads.

9. Use Precision Maintenance All the Time, Everywhere

This strategy gets your equipment precision installed and minimizes microstructure stress in components. You do top quality maintenance at the start so you do less maintenance less often later.

10. Practice Operating Degradation Management

The way equipment is operated can be tuned so that it suffers a slower rate of parts wear and tear and does not suffer surging overloads loads and stresses. The maintenance decreases and the operating profits rise when you introduce and improve degradation management methods and practices.

In the Plant Wellness Way you develop and use ideal operating procedures so all equipment is run in the best way to maximize life cycle operating profits.

11. All Maintenance Work is Error-Proofed

No failures from human error is allowed when maintenance people work on plant and equipment. It needs maintenance procedures with measurable task quality standards that insure work quality assurance no matter who does the work.

When you develop a Plant Wellness Way maintenance procedure for doing maintenance work you build-in protection against the chance of human error and maximises service life.

12. Do the Maintenance that Delivers the Maximum Life Cycle Operating Profit

The right maintenance to do is always the maintenance that brings the most operating profit over the life of the equipment. The only way to know what maintenance makes the most money is to do an economic model of your maintenance choices and adopt the most profitable option.

13. Work in Teams; Decide in Teams

Teamwork greatly improves the certainty of success. When people cooperate by sharing their knowledge, and help each other to make good decisions through questioning, research and discussion, the group decisions are more holistic in their considerations and usually work better than the choices taken by people who worked alone.

14. Change the Target to Change Your Game

To win a soccer game you must be able to kick the ball into the goals more often than the other team. If you want to travel to a holiday destination you first must choose where to holiday. If you want quality maintenance results you must first set quality maintenance targets. Once you set a world class goal—like, halve the maintenance cost of your production—you must then change away from the old methods, since they won’t work. You must now find new answers to achieve the performance you want and learn how to do them masterly so you can get to world class levels.

Here are some examples of what to do: How to Win the World Cup the Plant Wellness Way.

 

All the best to you,

Mike Sondalini
Managing Director
Lifetime Reliability Solutions HQ