Preventive Maintenance Planner Shows Preventive Maintenance Schedule
How to Calculate Replacement Asset Value for Assets and Equipment Purchased in Foreign Currency
When calculating the replacement asset value fo items brought overseas, factor the effect of the difference in exchange rate into the calculation.
[Read more…]Ahmed asks:
How can we calculate replacement asset value (RAV) of a plant? We have 100’s of equipment in our three plants and we cannot contact 100’s of Vendors to tell us today’s equipment value. We have only the Capitalization Cost or installed historic value of assets.
The oldest plant was installed 6 yrs back (Aug 2015) for a total plant or asset value in our accounting record of 10 MMPKR. When the plant was installed 1 USD = 100 PKR and now after 6 yrs the exchange rate is 1 USD = 172 PKR. We took the capitalization cost of 10 MMPKR and calculated replacement asset value at today’s worth as 10 * 172/100 MMPKR.
Process Instruments For Difficult And Corrosive Environments
There is always a degree of uncertainty in selecting instrumentation for difficult or corrosive environments. Material selection for chemical compatibility involves a strained decision between cost and equipment reliability and longevity. The other major uncertainty is whether the instrument is appropriate for the application – will it repeatedly give truly representative readings all it’s operating life? This article presents a list of instrumentation successfully used in a range of difficult and chemically demanding environments.
[Read more…]Maximizing Maintenance Work Quality and Equipment Reliability in Shutdowns
A presentation by Mike Sondalini at the Shutdowns and Turnarounds 2011 Conference.
The presentation covers:
- The connection between maintenance work quality and the time to the next breakdown.
- Using the Taguchi Loss Function to explain why work quality is important.
- Effectively specifying and measuring maintenance work quality requirements for shutdowns.
The Plant Wellness Way Difference
The Plant and Equipment Wellness Way lets organizations make their operating assets world class reliable so they can enjoy operational excellence success. A Plant Wellness Way EAM System- of-Reliability puts the reliability processes, skills, paradigm, and culture into companies that creates world class reliability and operational excellence.
[Read more…]Behaviour Based Safety Program: A Scientific Solution to Getting the Right Safety Practices Used in Your Workplace
Behavioural Based Safety (BBS) involves peer reviews of fellow workers’ safety practices. You use members of your workforce who take five minutes out of their day to observe a colleague at work and see if they are truly doing safe work practices
Use of a Behaviour Based Safety Program has seen an exponential rise in recent years. A number of eminent psychologists believe deeply in it, and in its ability to gain positive workplace safety results
Workforce behavioural observation, behavioural based safety, and a behaviour based safety program all involve observing people doing their work and seeing the safety behaviours they use. They are a proactive approach for getting workplace safety rather than a reactive approach to force safety improvement. The use of BBS is proactive because it gets shopfloor people working together to identify their hidden workplace hazards. It also gets unique data on your employees’ interaction with the hazards they have around them.
[Read more…]Highly Reliable Cyclo-Drive Gearboxes With Grease Lubrication
The cyclo-drive gearbox is a variation of a planetary gearbox. They have the added advantage of not using gear teeth to drive the shafts; rather they use an internal offset cam arrangement to drive rolling pins that turn a cycloidal wheel inside the gearbox. The rollers are capable of taking 500% overload without breaking the gearbox. One other benefit of the cyclo-drive gearbox for users is that many models are grease filled and do not use oil.
[Read more…]Three Key Lessons You Wish You Knew 20 Years Ago
Written by Mike Sondalini as a memo to his younger self, the content has been adapted into an article format. Given the depth of detailed information contained, this article is better considered a technical document. It summarizes Mike’s key learnings from decades of research, consulting, and training in the Plant Wellness Way EAM methodology.
[Read more…]Beware of the Dangers of a Sample Size of One in Business Process Improvement
Modelling your process improvement initiative on another organization’s success is foolish—they are but a sample size of one!
A sample size of one success can also be due totally to luck. To guarantee your process improvement will be a complete certainty you must have repeated proof that what you copy will bring sure success to you too
We love great success stories: The wizard entrepreneur; the person who crusaded for a worthy cause; the champion athlete; the financial guru; the innovative business solution with astounding results; the failing firm that turned their fortunes around; the penniless emigrant whose wits made them wealthy. Those stories are inspirational. They challenge us to be better. They make us want to achieve more in our life roles and with our lives.
[Read more…]How Plant Wellness Way Sites Get Zero Failures
The prime role of Maintenance is to reduce operating risk. Maintenance serves a business well when its use leads to lower production costs than using other choices that could have been taken. Too many managers think that they must maintain plant and equipment. Maybe you do and maybe you don’t. Maintenance is expensive and, as far as it is safe, use less costly answers. But if you do choose to do maintenance, then you ought to pick an operation’s maintenance strategy mix based totally on its effectiveness in delivering the least operating costs for the least maintenance cost.
[Read more…]Acid Sparge and Acid Sparging
Acid Sparge And Acid Sparging. When you want to introduce acid directly into a liquid below its surface a sparge pipe is used. It is necessary to select materials that are compatible with the chemicals and the process. This article explains the issues to address when selecting the sparge pipe materials for injecting acid into a process reactor and what to consider when designing and installing the sparge pipe into such vessels or tanks.
[Read more…]Big Difference Between Maintenance Planner and Scheduler
Maintenance Planner and Scheduler are Two Separate Roles. Planning is Always Done Before Scheduling
Planning maintenance work means developing the work breakdown structure activity by activity, including buying parts and services. Scheduling maintenance work means organizing and coordinating resources so a job is done on the agreed date.
A lot of people mistakenly think that maintenance scheduling is maintenance planning. They are not the same. There is a big difference between the two functions. The job description might say Maintenance Planner and Scheduler, but in reality they are two roles. Maintenance Planning needs to be done before you can do maintenance scheduling. One person may be tasked with the maintenance planning and scheduling functions, but each has its own duties and responsibilities.
First comes maintenance planning, and then you do maintenance scheduling. A maintenance work pack must be developed and completed in full first, so that comprehensive scheduling can be done using the work pack.
[Read more…]Do Only the Engineering, Supply Chain, Operations, and Maintenance that Gets World Class Reliability Success
A PWW EAM SYSTEM-OF-RELIABILITY ENSURES WORLD CLASS RELIABILITY AND OPERATING PROFIT FROM YOUR ENGINEERING, SUPPLY CHAIN, OPERATIONS, AND MAINTENANCE STRATEGY, METHODS AND PRACTICES
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Build your Engineering, Supply, Operations, and Maintenance processes to get world class reliability with the fewest resources and least costs
Making great choices that get world class reliability for your company is what you do with Plant Wellness Way Enterprise Asset Management methodology.
The Purpose of Maintenance of Plant and Equipment in Industrial Operations
Introduction to the Concepts and an Overview of the Purpose of Maintenance at the Turn of the 21st Century
Maintenance management is a key element of enterprise asset management and applies for the whole lifetime of your physical assets. The purpose of maintenance is much more than ‘fixing things up’; it is the appropriate management of asset health for its lifetime.
The philosophy that “a stitch in time will save nine” is very appropriate and is an important part of maintenance. On operating plants where this approach is formally recognised and acted upon, there is a very significant lift in the reliability of the plant.
[Read more…]Air Mover and Air Amplifier Problems.
Air Mover And Air Amplifier problems! Touted as great maintenance savers and a very efficient means of moving large volumes of air, they can in fact be extremely energy hungry. Based on using a small amount of compressed air to draw through a large amount of entrained air they can cause huge energy waste if an air compressor is run in order for the air mover to operate. It is wasteful to install an air mover on a plant air system unless the air compressor is always running well under peak demand.
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