Plant Wellness Way contains multiple concepts uniquely combined in the methodology. Expand your understanding of the methodology's foundational science and principles with these resources.

Deepen your understanding of the Plant Wellness Way Enterprise Asset Management methodology, science, and philosophy with these articles. Written for easy digestion of the processes and concepts discussed.

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3 Key Lessons You Wish You Knew 20 Years Ago

Originally written by Mike Sondalini as a memo to his younger self, this article has been adapted to provide you with his key learnings from the past two decades of research, consulting, and training experience.

A CMMS is Barely 5 Percent of a Complete Holistic Enterprise Asset Management System

A Computerised Maintenance Management System (CMMS) is only used during the operational phase of an enterprise. Whereas an Enterprise Asset Management System (EAM system) covers all life cycle phases of operating assets.

Videos of Individual Slides Presented at Charleston, USA, Training 2011

View the Plant and Equipment Wellness Way Enterprise Asset Management training course delivered in Charleston, USA by Mike Sondalini as he discusses key aspects of the Plant Wellness Way Methodology.

How the Plant Wellness Way EAM Methodology Builds an Operating Asset Life Cycle Management System

Plant Wellness Way Enterprise Asset Management methodology requires its users to ensure the entire asset life cycle is designed and built to eliminate plant and equipment failures of every type.

Articles on Reliability

If You Still Suffer Equipment Breakdowns, then Your EAM System has Failed (to Stop the True Root Causes)

An Enterprise Asset Management System is meant to forever eliminate plant and equipment failures and thus underpin operational excellence performance. Only when an EAM System is holistic can world class reliability be achieved.

Defining Risk and World Class Reliability

This article “Defining Risk and World Class Reliability” outlines key concepts than an organisation needs to be aware of to bring about optimal asset health by removing risks and managing their causes.

Calculating Failure Rates

Statistics and probability are used to calculate the failure rate of machines and parts. Keeping detailed records of how and why assets fails allows for predicitions to be made about possible future failures.

How to Better Understand Your Business Processes by Plotting Their Run Chart and Frequency Distribution

Here is an explanation and example of how to analyse and improve business processes by charting existing historic data. These plots help you understand and learn why a process behaves as it does in your company.

Deliberately Create Reliability

Reliability is an outcome that can be created. It is the result of the parameters, processes, and assets that a company uses. By designing these to prevent the causes of failure from occuring, reliability can be created.

Rate of Occurrence of Failure

ROCOF curves are the sum of all the individual components which fail across the service life of an asset. They provide valuable insight into how and why parts fail, and what can be done to improve reliability.

Articles on Precision Maintenance

15 Ways to Remove Operational Risk

Achieve healthy components and healthy machinery with these 15 precision maintenance targets. Listed with thier appropriate tolerances, they will ensure your operations achieve optimal reliability.

Precision Quality Standard Zones

An industry example which demonstrates the financial and operational value of using precision quality standards. When equipment components are operated within their precision quality standard zones, the microstructure stress is reduced.

Articles on Risk and the Physics-of-Failure

Root Cause Failure Analysis Using Physics of Failure Factors and Failure Cause Mechanism Guidewords

This equipment root cause failure analysis technique is used to list all the possible root causes of a component’s failure. It applies Physics of Failure science to identify the conceivable ways a part could fail while in service.

Producing Zero Operational Risk

Risk is the likelihood that a component will fail, and operational risk is a mathematical formular. This formula contains variables which can be broken down, manipulated, and controlled to achieve the desired outcome.

Designing with Physics of Failure

Engineers that design machines intentionally use Physics of Failure understanding to prevent breakdowns. They make decisions about the materials-of-construction for components to ensure a ‘safety factor’ is included.

Preventing Failure Using PoF

By understanding Physics of Failure it is possible to implement changes in the operating processes of machines to prevent failure. The easiest way this can be done is by keeping components in their precision operating zones.

How Your Asset Business Hierarchy Risk Impacts the Plant Wellness Way EAM System Design

All businesses want to remove operational risks caused by the organisation’s physical assets. Every equipment failure causes productivity and profit losses, often costing 10 to 30 times more than the maintenance cost to do the repair.

Physics of Failure

Physics of failure (PoF) is the understanding of the microstructure science behind how and why parts fail. There are two main types of failure of parts – degradation and deformation.

Eliminating Microstructure Failures

By preventing component’s microstructure from being degraded or damaged, you are preventing failure from occuring. If this is achieved at every stage of an asset’s life cycle it will provide exceptional reliability.

Asset Life-Cycle Management for Zero Defects and Risk

This article explores the common life-cycle of a physical asset, and the potential errors that can occur in each phase. These errors cause defects which contribute to breakdowns, losses, and wastes during operation, and shorted lifetime.

Articles on Standard Operating Procedures

ACE 3T Standard Operating Procedure Puts Quality Assurance and Quality Control into EAM Systems

An Accuracy Controlled Enterprise(ACE) 3T standard operating procedure sets specific quality requirements for each task of a job to help the doer do them right first time, every time. The 3T’s are TargetTolerance-Test.

How to Use SOPs to Achieve Zero Failure Operations

This article contains a weatlth of knowledge about how to determine, design, and implement effective SOPs. Standard Operating Procedures will acheive the best outcomes with the ACE 3T process explored here.

Equipment Failure Probability Density Curves

This article uses Failure Probability Density Curves in a series of activities that illustrate the power of SOPs. By charting the historic failure events of equipment, it is possible to identify how work processes can be changed to improve reliability.

Articles on Operational Excellence and EAMs

That’s Not a EAM System. THAT’S A EAM SYSTEM!

Here is introduced a holistic andforward-looking enterprise asset management (EAM) model (1). It guides an organization’s leaders as to how to profit greatly from their EAM system.

Aiming for Operational Excellence

Operational Excellence, regardless of how it is phrased, is to produce the best quality products at the lowest cost for maximum profit. As such, this should be the natural aim of all buinesses.

How to Create a PWW EAM System

The PWW EAM methodology is a framework that creates a complete asset life cycle management system. You design, build, and embed processes that specifically get outstandingly reliable plant and equipment performance.

True Cost of Maintenance

Maintenance department budgets are often a hot-topic of conversation, but have you explored the true cost? By focusing on equipment reliability maintenance costs will become more predictable and reduce overall.

Enterprise Asset Management for World Class Reliability the Plant and Equipment Wellness Way

Enterprise asset management (EAM) is the system of organization, processes, practices, knowledge, and information management used to optimize the value gained from your physical assets.

Changing an EAM System for Operational Excellence Success

Rather than going from policy to practice, PWW starts with how to create a healthy environment for parts microstructure to practice.

Business Risk Hierarchy

This article outlines what an organization needs to be aware of to bring about optimal asset health by removing and managing risks. It contains processes and analysis tools to develop a system that fully supports asset health.

Total Cost of Downtime

The total costs of downtime are far beyond what many companies budget for. By understanding the true costs of failure you are able to build a solid business arguement for higher quality maintenance and operational performance.

Articles on Series and Parallel Arrangements

Reliability Block Diagrams

Reliaility Block Diagrams are a tool used by reliability engineers to represent and calculate the reliability of a system. Easy to use, this is a powerful tool to understand where reliability improvements can be made.

Reliability Properties of Series and Parallel Systems

Series and Parallel systems have key reliability properties which impact on business and operational decision making in 7 key ways. This article explores the mathematical knowledge needed to understand and utilise them.

Achieving Highly Reliable Systems

There are only two ways to get high system reliability, with exceptional work performance or parallel series. This article explores the mathematics behind this concept and reveals key concepts to acheive outstanding operational reliability.


Guarantee World Class Reliability Success for Yourself. Industrial and Manufacturing Wellness: The Complete Guide to Successful Enterprise Asset Management

Industrial and Manufacturing Wellness: The Complete Guide to Successful Enterprise Asset Management explains how to use system reliability engineering principles to design and build robust, reliable, and self-improving companies. This book explains how to develop and use integrated business systems to achieve optimal production performance and make operating fortunes.

Written by operating asset management expert Mike Sondalini, the book explains why and how Plant Wellness Way EAM methodology ensures engineering, operating, and business processes and workflows that get operational excellence.

Plant Wellness Way EAM is explained in Industrial and Manufacturing Wellness book

I have been focusing on RCM while at Toyota Motor Manufacturing NA. When I found Industrial Maintenance Wellness it bridged the gap between operational failures and component molecular failures. Mike’s process are excellent and the documents he has develop shows deep understanding of how components fail and how to prevent performance loss. I recommend it as part of a any library, for studies in reliability or team, as training tool it excels reducing the leaning curve.

Mike Burgett

United States