Further Reading

Plant Wellness Way contains multiple concepts that are unique to the methodology, expand your understanding of the methodology 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.


Click through to each section

Reliability    –    Precision Maintenance    –    Risk and Physics-of-Failure    –    Standard Operating Procedures    –    Operational Excellence and EAM    –    Series and Parallel Arrangements

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.

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.

Articles on Reliability

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.

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 imporve 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

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.

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

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

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.

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.

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 reliability engineering principles to design and build companies that are robust, reliable, self-improving, integrated business systems best suited for achieving optimal results.

 Written by asset management expert Mike Sondalini, creator and author of The Plant Wellness Way, this revolutionary work goes beyond basic plant management. Instead, it reveals a completely new way to engineer and implement business processes and work flow strategies that deliver overall operational excellence.

I read this book thinking that it would be like many of other books in this area – full of theory. However, I found soon that it is not just theory!! The author builds on the theory by giving a logical framework and case studies. […] Highly recommend it.

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