Blog
Maintenance with method, explained in practice
Metrics with the math worked out, failure analysis, maintenance plans and the path from reactive to predictive. Written for the people who plan, run and manage maintenance.
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Management
What is a CMMS, and when the spreadsheet stops working
Assets, work and resources linked together, and the signs the spreadsheet has hit its limit.
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Management
CMMS, EAM or ERP: which system fixes your maintenance
Three acronyms, three different questions, and five questions to decide.
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Management
Spare parts inventory: how many of each part to keep
Reorder point for what moves, and the risk math for the critical spare.
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Management
How to implement a CMMS in 90 days without a data graveyard
Pilot area, short tags, failure codes and three KPIs in 90 days.
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Management
Mobile work orders: what changes when the work order goes to the field
No signal, few taps, photos and checklists: what to demand from the app.
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Management
Pareto chart in maintenance: find the 20% that stop the plant
By downtime hours, on two levels, with the mistakes that make the chart useless.
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Management
Equipment criticality: how to decide what comes first
Four questions, three classes and what each one gets in the plan.
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Reliability
Why bearings fail early (and what the technician controls)
Lubrication, contamination, mounting, misalignment and current: and how to read the part that came out.
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Metrics
What an hour of downtime costs: the number missing from the report
Lost margin, recovery and penalties: the same replacement cost 11 times more as an emergency.
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Reliability
The failure that keeps coming back: when 5 whys aren't enough
Ishikawa, FMEA and fault tree applied to a pump that broke four times.
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Management
A maintenance SOP the technician actually uses
One page, steps with numbers, done criteria, and on the technician's phone.
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Reliability
Thermography, vibration, ultrasound or oil: what each technique catches
The P-F curve, what each technique detects first and the order to start in.
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Metrics
Maintenance backlog: how to calculate it and read the trend
How many weeks the team would need to clear the queue, and what the curve is warning you about.
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Metrics
OEE in practice: the six big losses and where maintenance comes in
Availability, performance and quality, the six losses and the ones nobody records.
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Reliability
Equipment reliability: the odds of not failing in the next few hours
Why only 37% of equipment reaches its MTBF without failing, and how to use that to decide.
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Management
Is your maintenance plan working? 3 KPIs to prove it
How much is planned, how much gets done on time and how much has to be redone.
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Management
What to record on a work order so the KPIs don't lie
What each field turns into later and the 7 mistakes that spoil MTBF, MTTR and backlog.
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Metrics
How to calculate MTBF and MTTR (with a step-by-step example)
The formulas, an example worked out by hand and the mistakes that make the metric useless.
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Metrics
The 5 components of MTTR: where your team really loses time
Detection, dispatch, diagnosis, waiting for parts and repair: the fix itself is usually the smallest part.
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Management
7 signs your maintenance is still reactive
Seven symptoms that are easy to recognize and the first step out of each one.
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Management
The maintenance maturity curve: from reactive to prescriptive
Five stages, how to know where you are and what changes to climb each step.
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Reliability
5 Whys in maintenance: root cause analysis of a real failure
A complete example, the common mistakes and how to record the cause so the failure doesn't come back.
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Compliance
HVAC maintenance plan: what to include and how to prove it's done
What the plan should contain, who prepares it and how to prove it was carried out.
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