What is the true value of systematic maintenance planning and scheduling? The answer varies by role—technician, crew supervisor, plant manager, or corporate leadership. For Technicians Experienced technicians recognize that a dedicated planning team acts as a live file clerk. Instead of juggling fra

Manufacturers worldwide are realizing that investing in reliability delivers extraordinary returns—often 10‑to‑1, 20‑to‑1, or even 50‑to‑1—unmatched in other areas. However, the path to reliability is not paved with silver bullets. Achieving it demands sustained effort and strategic investment. They

In 2008, the manufacturing sector began feeling the ripple effects of the first wave of baby‑boomer retirements. While many industries were affected, manufacturers faced a unique challenge: the scarcity of technically skilled workers needed to maintain increasingly sophisticated production lines, es

In many plants, myths about maintenance management persist—myths that are technically wrong yet still practiced because they feel politically correct or simply convenient. To truly improve equipment reliability, a plant must confront these myths and avoid the common pitfalls that sabotage success. T

More than 750 million viewers tuned in for Super Bowl XL this Sunday. Even if you’re not a Steelers or Seahawks fan, the event offers valuable insights for manufacturing leaders. If you work in a manufacturing plant or processing facility, consider using the game—and the surrounding hype—to illustr

A joint task force of management and labor leaders at American Airlines’ Maintenance & Engineering Base has announced a breakthrough initiative to generate $150 million in value creation, transforming the facility into a profit center by the end of 2007. The vision to transform the base from a t

Understanding the condition of lubricants is vital for uninterrupted plant operations. A robust oil analysis program tracks key wear indicators, compares them to historical data, and reveals trends. This approach uncovers contamination, lubricant degradation, abnormal wear, and sampling issues—trans

Success in a manufacturing environment hinges on two critical elements: skilled people and timely information. When leadership couples these with a culture of engagement, continuous improvement becomes inevitable. Leaders must cultivate an atmosphere where employees feel empowered to identify and so

Catalyst Paper Enhances Mill Performance with Ivara Reliability Initiative Leading North American producer of mechanical printing paper, Catalyst Paper also supplies de‑inked newsprint, market kraft pulp and containerboard. With five mills operating within a 100‑mile radius along the south coast of

Allied Reliability has announced the launch of a dedicated reliability engineering services division, designed to address critical gaps in today’s maintenance and reliability landscape. John Schultz, an Allied partner, explains that the new group tackles two pervasive challenges faced by manufacture

Turbine Generator Maintenance, Inc. (TGM) has officially merged its two legacy operations—Steam Turbine Services and Combustion Turbine Services—under the single, streamlined name Turbine Generator Maintenance (TGM). The rebranding, effective immediately, brings together 20 years of steam turbine ex

As editor of Noria Corporation’s Reliable Plant magazine, I invite you to the 2024 Lubed, Reliable & Lean Conference, held May 16‑18 at the Greater Columbus Convention Center.Our event is a convergence of three high‑impact tracks that drive continuous improvement: Lubrication Excellence, Reliability

Veteran reliability professionals recognize the power of Reliability‑Centered Maintenance (RCM) and its extensions—equipment, process, and plant design (RCD) and operation (RCO). Yet the sales arena often overlooks this critical lens. I argue that embedding reliability into the sales cycle is not ju

Maintenance Reduction 50 Percent is an ambitious target, but Toyota’s track record of eliminating waste makes it a realistic goal. The Georgetown, Ky., plant manufactures the Camry sedan, Avalon sedan, and Solara coupe and convertible. How do your plant’s metrics compare? For context, Toyota’s recen

I learned early in manufacturing that results follow inspection, not expectation. This simple truth is hard to apply consistently, yet it anchors purpose and cultivates a robust work culture. All too often, initiatives launch with enthusiasm only to fade as follow‑up evaporates. That erosion breeds

In the first two installments of this series, I highlighted the essential foundations for developing maintenance leaders. The core takeaways were: Leaders must define a clear vision before they can inspire others. Leadership is the art of guiding people to achieve shared objectives. Support and emp

In earlier posts I highlighted the most common frustrations that planners face and the undeniable value of thorough planning. Today I continue that discussion by exploring a key principle for effective maintenance planning: how planners should file information. This is Principle 3 in my Maintenanc

Back in 1995, I was presenting at a Chemical Manufacturers Association conference when a quiet voice in the back of the room interrupted: “What a load of bull!” The slide that triggered the comment showed that the industry’s best performers generate 55 % of their workflow through condition‑based mo

Relubrication decisions rarely fit into a simple black‑and‑white framework. In practice, a lubrication practice is either effective or it isn’t—there’s no middle ground. During a recent seminar I led, a mechanical supervisor argued fiercely against revising his plant’s lubrication routine. He boaste

When I tour mills, the most common question is whether to outsource maintenance. In this column, I explain which maintenance tasks are best kept in‑house and which should be contracted out, and why. Variability in workload A disciplined preventive‑maintenance program keeps daily and weekly tasks pre