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Mike Sondalini — Thought Leader

Author of Plant Maintenance, Maintenance Management, and Life Cycle Asset Management.


This author's archive lists contributions of articles and episodes.

by Mike Sondalini Leave a Comment

Introducing Industrial and Manufacturing Wellness

Introducing Industrial and Manufacturing Wellness

Plant Wellness Way EAM methodology uses systems engineering and life-cycle risk elimination to re-engineer your company and operational processes to get utmost asset reliability and maximum success and profits from your operating plant and equipment

You get optimal life-cycle asset management, production, and business processes delivering outstanding plant, equipment, and process reliability

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Example Accuracy Controlled Enterprise (ACE) 3T Job Procedure

Example Accuracy Controlled Enterprise (ACE) 3T Job Procedure

Example ACE 3T (Target-Tolerance-Test) Procedure with Reliability Standards: Machine performance is totally dependent on human beings. To address the problem of human error causing equipment failure, an Accuracy Controlled Enterprise sets best practice quality standards and uses 3T Target-Tolerance-Test work task quality control that assures high quality workmanship for high reliability results. Their work procedures are standardised so everyone follows the same methods to produce the same results, their training teaches people how to do craftsmanship work that creates outstandingly reliable plant and machinery. They create the reliability they want and as a result achieve operational excellence.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Road Tanker Design for Fast Unloading and Onshore Pump Drain Tank

Road Tanker Design for Fast Unloading and Onshore Pump Drain Tank

Road Tanker Compartment Design

Road Tanker Design For Fast Unloading And Onshore Pump Drain Tank. To completely empty a road tanker the compartments need to be designed to have a sump that permits total drain-out of the liquid from the lowest point. If a pump is mounted on the trailer, it is best mounted under the trailer. Where a pump is mounted on the tray or fenders it will cavitate at low tanker liquid levels. For an onshore unloading pump installation it is best to install a buffer tank between the tanker and onshore pump to let the road tanker completely drain-out before the pump starts cavitating. Tanker load-out pumps must have a very low net positive suction head requirement.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini 1 Comment

Calculating the Failure Rate of Parts

Calculating the Failure Rate of Parts

This simple example explains how to calculate the failure rate of parts, known as the Hazard Rate, using a drinking glass. Historic records, like maintenance, operating, supply chain, and financial information, are accessed to understand the situation being analyzed and gather modelling data. Once all necessary information is collected and the situation is investigated, then proposals to address and solve the problems causing and permitting the failure to happen are selected and a business case is developed.

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

How Profit Contribution Mapping Turns Wasted Money into Outstanding Operational Productivity and Profits

How Profit Contribution Mapping Turns Wasted Money into Outstanding Operational Productivity and Profits

Value Stream Mapping is a business process improvement tool. It derives from the Toyota Production System where it was used to identify the seven wastes in a production process. It is now used across all business processes because the principle of finding and removing waste applies throughout every business.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Technological Inheritance Effect on Failure Rate, Defect Elimination and Reliability Effects

Technological Inheritance Effect on Failure Rate, Defect Elimination and Reliability Effects

Technological inheritance, defect inheritance, and quality inheritance transfer to the future. To create a better future for your organization you first must create a better past so it can later inherit the preordained successes you designed and imbedded into your company.

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Cheap Way To High Pumping Circuit Availability

Cheap Way To High Pumping Circuit Availability

Using Reliability Principles for a Cheap Way To High Pumping Circuit Availability. High plant availability is achieved by having redundant equipment that can be brought on-line as soon as the operating unit has failed. Redundancy is expensive as there are two items to buy, two to install and two to maintain at full operating capacity. There is an alternate option for maintaining high pumping circuit availability by designing quick methods to bring mobile equipment into the circuit when pumps are down. This article explains how to set-up piping for a mobile pump to maintain operation when the normal duty pump is out of use.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

Getting High Equipment Reliability

Getting High Equipment Reliability

These are the slides from Mike’s conference presentation at the SIRFRt CM & Lube Forum 2008 Conference.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Old Preventive Maintenance (PM) Out, New Preventive Maintenance (PvM) In

Old Preventive Maintenance (PM) Out, New Preventive Maintenance (PvM) In

PREVENTIVE MAINTENANCE STRATEGY IN A PLANT WELLNESS WAY EAM SYSTEM-OF-RELIABILITY

IN A PWW EAM SYSTEM-OF-RELIABILITY, PREVENTIVE MAINTENANCE STRATEGY IS TO REPLACE PARTS WHEN EXCESSIVE STRESS BUILD-UPS IN THEIR MICRO-STRUCTURE

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Day 2 Maintenance Planning Slides with Complete Explanations

Day 2 Maintenance Planning Slides with Complete Explanations

Welcome to Day 2 of the Maintenance Planning and Scheduling for World Class Reliability and Maintenance Performance 3-Day Training Course. I hope that you enjoyed Day 1 and found the maintenance and reliability concepts it contained useful.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Use An Isocorrosion Diagram To Recognize High Corrosion Situations

Use An Isocorrosion Diagram To Recognize High Corrosion Situations

Use an Isocorrosion Diagrams To Recognise High Corrosion Situations And Design Process Equipment Accordingly. A true story of how a high nickel alloy (Alloy 28) reactor was holed in 8 weeks by sulphuric (sulfuric) acid running down the inside wall. When the situation was reviewed in detail using an iso-corrosion diagram for the alloy in sulphuric acid it was obvious that such a problem would occur. The iso-corrosion curves clearly showed the huge corrosion rates that would happen at local contact points within the reactor. A clear and detailed understanding of how to use iso-corrosion curves would have highlighted the problem at the design stage.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

Annex SL Structure for ISO 55001 Asset Management Documentation in a EAM System Manual

Annex SL Structure for ISO 55001 Asset Management Documentation in a EAM System Manual

WHEN YOU BUILD AN ASSET MANAGEMENT SYSTEM FOR ISO 55001 CERTIFICATION THE ISO 55001 EAM SYSTEM MANUAL NEEDS TO COMPLY WITH THE ANNEX SL DOCUMENT STRUCTURE.

Here’s a practical way to create an ISO 55001 EAM system manual that covers all bases for both ISO 55001 certification and Annex SL requirements. Annex SL stipulates ten sections that every management system built to an ISO management system standard must contain. But matching legacy enterprise asset management 9EAM) system documents to Annex SL sections can be tricky.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Machine Vibration Isolation – Theory and Practice

Machine Vibration Isolation – Theory and Practice

1. Application.

Any engineer with known expertise or responsibilities in the area of ‘vibration’ will be asked sooner or later to advise on a vibration isolation problem. While the principles of vibration isolation are relatively simple to understand the practical application requires some design skills and a good understanding of the vibration source or sources.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Testing and Proving Plant Wellness Way Enterprise Asset

Testing and Proving Plant Wellness Way Enterprise Asset

Management at Industrial and Manufacturing Sites

Full of new, powerful solutions, the Plant Wellness Way EAM methodology ensures operations and companies get to world class equipment reliability

Let a Plant Wellness Way EAM System-of-Reliability halve your Annual Maintenance Costs

People investigating the Plant Wellness Way enterprise asset management (PWW EAM) methodology want to know exactly what happens when they use it, especially how the analysis and implementation will be done in their own operation. A PWW EAM System-of-Reliability brings you three massive business advantages:

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Workplace Safety Culture Changes when You Embed ACE 3T OHS Standards in Your Work Procedures

Workplace Safety Culture Changes when You Embed ACE 3T OHS Standards in Your Work Procedures

Design your safety system with the workplace safety culture and safety practices you want

Use the ACE 3T culture change technique to design, teach and adopt the best safety culture into your organization

Here’s a workplace safety culture change fact we’ve known about for a long time. This quote from G. J. Hofstede in his book, Cultures and Organisations, explains a lot about how you create the right workplace safety culture.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

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