sondalinilaura 320corrw215pg_Layout 2 3/24/16 3:25 PM Page 1 INDUSTRIAL and Manufacturing WELLNESS The Complete Guide to Successful Enterprise Asset Management Mike Sondalini INDUSTRIAL PRESS, INC. sondalinilaura 320corrw215pg_Layout 2 3/24/16 3:25 PM Page 2 Industrial Press, Inc. 32 Haviland Street, Suite 3 South Norwalk, Connecticut 06854 Tel: 203-956-5593, Toll-Free: 888-528-7852 E-mail: [email protected] Library of Congress Cataloging-in-Publication Data Name: Sondalini, Mike, author. Title: Industrial and manufacturing wellness: the complete guide to successful enterprise asset management / Mike Sondalini. Description: 2nd edition. South Norwalk, Connecticut: Industrial Press, Inc., [2016]. Includes bibliographical references and index. Identifiers: LCCN 2016008105; ISBN 9780831135904 (hardcover: alk. paper); ISBN 9780831194031 (ePUB); ISBN 9780831194048 (eMOBI); ISBN 9780831194024 (ePDF) Subjects: LCSH: Plant maintenance—Management. Industrial equipment—Maintenance and repair. Production management. Production planning. Classification: LCC TS192 .S675 2016; DDC 658.2/02—dc23 LC record available at http://lccn.loc.gov/2016008105 ISBN print: 978-0-8311-3590-4 ISBN ePUB: 978-0-8311-9403-1 ISBN eMOBI: 978-0-8311-9404-8 ISBN ePDF: 978-0-8311-9402-4 Copyright © 2016 by Industrial Press, Inc. All rights reserved. This book, or any parts thereof, with the exception of those figures in the public domain, may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the copyright holders. Sponsoring Editors:Taisuke Soda and Judy Bass Managing Editor:Laura Brengelman Developmental Editor:Deborah A. Ring Interior Text:Janet Romano-Murray Cover Design: Ryan Maxwell and Janet Romano-Murray industrialpress.com ebooks.industrialpress.com 10 9 8 7 6 5 4 3 2 1 sondalinilaura art320pg_Layout 2 3/7/16 3:57 PM Page 3 DEDICATION In memory of quality management guru W. Edwards Deming. Your vision of what is possible continues to guide and inspire. sondalinilaura art320pg_Layout 2 3/7/16 3:57 PM Page 4 sondalinilaura art320pg_Layout 2 3/7/16 3:57 PM Page 5 T C ABLE OF ONTENTS PREFACE ix INTRODUCTION xi Building a System of Reliability xi Plant Wellness Way Overview xii The Six IONICS Processes xiii Plant Wellness Way Vision xv CHAPTER 1: RELIABILITYOFWORK, PROCESSES, AND MACHINES 1 Job and Work Process Reliability 1 Transferred Defect Inheritance and Quality Inheritance 4 Business Process Reliability 5 Industrial Equipment Reliability 7 The Control of Series Process Reliability 10 CHAPTER 2: THEPHYSICSOFFAILURE 19 The Cause of Machinery and Equipment Parts Failure 20 The Physics of Failure 23 Equipment Reliability Cliffs 29 CHAPTER 3: VARIABILITYIN OUTCOMES 37 Observing Variability 37 Controlling Process Variation 47 Setting Engineering and Maintenance Quality Control Standards 54 CHAPTER 4: PREVENTING LIFE-CYCLE RISKS 59 Raising the “R” 61 The Plant Wellness Way 62 Asset Management Strategy from Physics of Failure Factors Analysis 65 CHAPTER 5: PROCESS 1—IDENTIFYBUSINESSAND OPERATIONALRISKS 79 Summary Description of Process 1: Risk Identification 79 Start with a Process Map of the Situation 82 Introduction to Total Defect and Failure Costing 87 CHAPTER 6: ASSETMANAGEMENTFOR PLANTWELLNESS 93 Successful Asset Management by Design 94 Analyze Operational Consequences during Project Design 96 Enterprise Asset Management the Plant Wellness Way 100 v sondalinilaura art320pg_Layout 2 3/7/16 3:57 PM Page 6 vi TABLEOFCONTENTS CHAPTER 7: OPERATING EQUIPMENTRISKASSESSMENT 103 Estimating Risk 103 Equipment Operating Criticality 104 CHAPTER 8: PROCESS 2—ORDER RISKSBYIMPORTANCE 109 Summary Description of Process 2: Rating Operating Risk 109 Assessing Operating Equipment Risk 110 Risk Assessment and Risk Mitigation Templates 113 Performing an Operating Criticality Analysis 114 CHAPTER 9: REMOVING RISKSAND RAISING RELIABILITY 117 Identifying Equipment Reliability Growth Opportunities 118 Developing a Highly Successful Equipment Risk Prevention Plan 123 CHAPTER 10: CHANCE REDUCTION RISK MANAGEMENT 135 Impact of the Choice of Risk Reduction Strategies 135 Three-Factor Risk Analysis 142 CHAPTER 11: SELECTING RELIABILITYSTRATEGY 145 Maintenance Is a Risk Control Activity 146 Physics of Failure Reliability Strategy Analysis 153 Documenting Your Plant Reliability, Maintenance, and Operating Strategy 156 CHAPTER 12: PROCESS 3—NUMERATE RISK ELIMINATION OPTIONS 161 Summary Description of Process 3: Select Risk Control Strategy 161 Plant Wellness Way Risk Elimination and Reliability Methodology 163 Selecting and Implementing High-Reliability Strategy 170 CHAPTER 13: THEACCURACY-CONTROLLED ENTERPRISE 175 The Precision Principle 175 Creating Standard Operating Procedures to Become World Class 177 Making Your Organization an ACE 181 CHAPTER 14: PRECISION MAINTENANCE SKILLSAND STANDARDS 187 Financial and Operating Benefits of Precision Maintenance 187 The Importance of Precision Standards for Machine Reliability 189 Precision Maintenance Program 194 CHAPTER 15: PROCESS 4—INTRODUCE RISK CONTROLSOLUTIONS 203 Summary Description of Process 4: Introduce Risk Controls 203 Setting ACE 3T Requirements 205 Examples of Accuracy-Controlled Procedures 206 Competency Assessment and Training Plan 217 Cross-Functional Knowledge Teams 217 sondalinilaura art320pg_Layout 2 3/7/16 3:57 PM Page 7 TABLEOFCONTENTS vii CHAPTER 16: RELIABILITYGROWTH 219 Failure Patterns and Failure Modes 219 Reliability Growth Cause Analysis 220 Setting Reliability Standards That Deliver Outstandingly Reliable Equipment 228 CHAPTER 17: MEASURINGTO IMPROVE PERFORMANCE 237 Monitoring a Process and Its Process Steps 238 Monitoring and Measuring Maintenance 246 CHAPTER 18: THECHANCEOFSUCCESS 249 Estimating the Chance of Process Success 250 Estimating the Chance of Equipment Success 252 CHAPTER 19: PROCESS 5—CONTROLOPERATIONALPROCESSES 259 Summary Description of Process 5: Risk Monitoring and Control 259 Engineer Processes to Run Successfully 260 CHAPTER 20: FAILURE ROOTCAUSE PREVENTION 265 Improve the Process Design 266 Behaviors of High-Reliability Organizations 268 Limitations of Our Materials of Construction 269 CHAPTER 21: CHANGE MANAGEMENTFORWORKPLACE INNOVATION 271 Install Quality Management in Operations and Maintenance Processes 271 Change Your Goals to Change Your Game 272 The “Change to Win” Team-Based Business Improvement Program 273 CHAPTER 22: PLANTWELLNESS INDEX 277 Potential for World-Class Reliability 277 Organizational Capability to Have High Reliability 277 CHAPTER 23: PROCESS 6—SYNTHESIZE IDEASTO CONTINUOUSLYIMPROVE 283 Summary Description of Process 6: Continuous Risk Elimination 283 Find the Hidden Risks and Eliminate All of Them 285 BIBLIOGRAPHY 287 INDEX 289 ABOUTTHEAUTHOR 301 For additional online materials referred to throughout the text, visit Industrial Press’s website at http://industrialpress.com and go to the page for Industrial and Manufacturing Wellness, where a link to these dowloadable files is provided. sondalinilaura art320pg_Layout 2 3/7/16 3:57 PM Page 8 sondalinilaura art320pg_Layout 2 3/7/16 3:57 PM Page 9 P REFACE This book contains the complete Industrial and Manufacturing Wellness (IMW) asset management solution for creating and sustaining outstanding production plant and equipment reliability. It evolved from the Plant and Equipment Wellness concepts for perpetual machinery health. The methodology is also known by the equally meaningful and shorter name Plant Wellness Way. The full explanation and examples make this book a user manual. The book is accompanied by spreadsheet templates and support documents that are available online. You can access these resources at the pub- lisher’s website, http://industrialpress.com, then go to the page for Industrial and Manufactur- ing Wellness, where a link is provided to the online materials. The Plant Wellness Way methodology is based on sure materials science, reliability engineering facts, good financial management sense, and risk management best practices. Its purpose is to achieve world-class physical asset performance so that all industrial and manufacturing operations can reach Operational Excellence. Because IMW is based entirely on the laws of reliability engineering, risk elimination, and microstructure physics, you can get Operational Excellence success without using the methods of Lean or Six Sigma. In January 2014, the ISO 55000 physical asset management series was released. It is gratifying to see the faultless match between the methods and outcomes of the Plant Wellness Way and the re- quirements of the ISO 55001 asset management standard. The Plant Wellness Way methodology lets you design and build a highly successful enterprise asset management system that will also fully sat- isfy ISO 55001 certification. It does so using low-cost, comprehensive methods that will ensure you make the best choices for your operation. Heartfelt thanks go to Taisuke Soda, former editorial director at Industrial Press, Inc., for his de- cision to publish this book, and to his successor, Judy Bass. Thanks go to Laura Brengelman, man- aging editor at Industrial Press, for her professional and practical publishing advice. It’s been a pleasure to work with project editor Deborah A. Ring. She turned a rough draft manuscript into a highly readable book and, in that process, made me a better writer. Thank you as well to Janet Ro- mano-Murray for creating a user-friendly book layout. An author’s family is always impacted by the writing of a book, and deep gratitude goes to my wife Sue for her patience and support over the months of composing and then editing the manuscript. It is unlikely that all that is written in this book is perfectly right. Most of what we think is true today will be shown to be not quite so in the future—there are always better, more complete, and more effective answers to be found. That’s the way it has been since the dawn of civilization. Hu- manity advances gradually by doing, failing, and learning. The path to Industrial and Manufacturing Wellness will continually improve and become simpler and more effective as the asset management and reliability body of knowledge grows ever truer and our methods and techniques get ever more successful. Right now, you have in your hands the best possible method for getting outstanding phys- ical asset reliability success in industrial and manufacturing operations: the Plant Wellness Way. Mike Sondalini www.lifetime-reliability.com April 2016 ix