In earlier posts I explained the power of planning and scheduling, and I outlined six principles that make planning truly effective. The last two articles focused on scheduling as a key productivity lever and introduced the first principle: the need for a planned backlog. In this installment, I’ll e

I spend a significant amount of time in plants, partnering with companies to craft strategic lubrication plans that enhance motor performance and reliability. Whether in pharmaceuticals, mining, steel, or food processing, the core question remains: how should we lubricate electric motors? For those

I was born in Pennsylvania and grew up near Philadelphia, a city famously dubbed the City of Brotherly Love. Home to Independence Hall, the Liberty Bell, the Philadelphia Phillies, and world‑renowned cheesesteaks, Philadelphia is also the birthplace of one of America’s most celebrated citizens: Benj

Mechanical failures in motors, drives, and other electromechanical equipment are the most common cause of production stoppages. Modern vibration‑based condition monitoring systems detect problems before they fail, reducing costly shutdowns and maximizing output. Why Wireless? Condition monitoring un

I am a shaft alignment trainer with extensive experience in performing alignment checks and corrections on process equipment. Below are my key observations: Most attention to precision alignment focuses on large, process‑critical machines. Maintenance departments are often downsized and prioritize

In the plant reliability community, we recognize that traditional diversity—race, gender, ethnicity—enhances decision‑making by broadening perspectives and fostering creativity. Yet, an equally critical dimension is functional diversity: bringing together professionals from all areas that shape or a

On August 23, United Airlines announced that it is exploring a spin‑off of the majority of its maintenance operations, a move that would affect its expansive repair base at San Francisco International Airport. The potential restructuring would impact roughly 2,800 employees, most of whom work in the

Singapore Airlines Selects Hamilton Sundstrand’s C.A.R.E. Program for Airbus A380 Fleet Singapore Airlines has chosen Hamilton Sundstrand’s Comprehensive Accessory Repair and Exchange (C.A.R.E.) program to manage and maintain the technical health of its Airbus A380 aircraft. The 10‑year exclusive ag

In manufacturing, the chain is only as strong as its weakest link. At Eaton Hydraulics in Shawnee, OK, Bruckner Supply—Eaton’s integrated supplier—keeps a vigilant eye on every detail to ensure that production never stalls. The plant relies on dozens of Okuma and Mazak machining centers that operate

For decades, maintenance leaders have debated the best way to gauge success. Traditional metrics—cost per unit, cost as a percentage of replacement value, or equipment uptime—focus on after‑the‑fact outcomes. This approach misses a critical opportunity: measuring the signals that predict those outco

Manufacturers are shifting from scheduled preventive upkeep to condition‑based and predictive maintenance to protect high‑value assets and curb repair costs. Key to this shift is monitoring the health of crankcase, hydraulic, motor bearings, and gear lubricants in heavy machinery and plant equipment

Life Cycle Institute, a leading authority in asset reliability, is now accepting registrations for its Maintenance Planning and Scheduling Course. Over five intensive days, participants will gain the skills needed to manage material costs, overtime, and repair expenses while coordinating maintenance

Poor plane maintenance practices are going unchecked, threatening a major incident, warned aircraft engineering groups on September 21. From 2004‑2006, the Association of Licensed Aircraft Engineers (Alae) documented roughly 1,700 maintenance failings or regulatory non‑compliance incidents across Eu

As we conduct lean assessments across manufacturing sites in the region, one area that consistently lags is equipment maintenance. Many facilities still operate with a reactive mindset: equipment is expected to fail, preventive plans are vague or ignored, and spare parts are stored under conditions

Below is a comprehensive overview of how maintenance is evolving across the globe, the key regional strengths and challenges, and a proven framework for continuous improvement. Regional strengths and weaknesses in maintenance Current trends in maintenance management The value of maintenance associa

Eight Proven Ways to Adopt Multicultural Leadership As the U.S. workforce evolves, so must our leadership models. Juana Bordas, author of Salsa, Soul and Spirit: Leadership for a Multicultural Age (Berrett‑Koehler, 2007, ISBN‑10: 1-57675-432-4, ISBN‑13: 978-1-57675-432-0), argues that businesses thr

Reliability‑Centered Maintenance (RCM) is a systematic method for crafting an optimized maintenance policy for physical assets. Originating in aviation, where it has proven highly effective, RCM has increasingly been adopted in manufacturing and process industries. While some organizations have s

Introduction The 732‑megawatt coal‑burning plant at Alcoa’s Warrick Operations in Newburgh, Ind., once appeared on the company’s 72‑page annual report as a liability. Three separate mentions of deficient reliability in 2001 cost Alcoa $45 million pre‑tax and highlighted a serious operational failure

I wrote this column for plant leaders who want to improve equipment reliability but feel trapped by rigid budgets. If your fiscal year begins on January 1, the months of November and December are the perfect window to design a jailbreak strategy. Most of you already recognize the term “budget jail.”

The optimal window for planning routine maintenance is a single week. While plant engineers may strategize on multi‑year horizons and execute detailed shutdowns, day‑to‑day productivity hinges on a concise weekly plan.In many facilities, maintenance is treated as a reactive function: crews respond t