Creating Your Wear Plate Action Plan

We worked with a maintenance manager who was recently thrust into a new department. He was nearly overwhelmed because he was out of his element.

Up until now he had been trained as an electrician at a large papermill who worked his way up to Electrical & Instrumentation supervisor.

The company moves people around into different departments every couple of years. We had met in passing on a couple of earlier projects, so we knew each by sight. But now he was in an area with little personal experience.

It is not your fault when the company makes you in charge of mechanical maintenance for a production area with no training. Worse, they had little documentation or background on what failed previously, what worked or if it is doing great.


Here you see a chain deck with 4 layers of ¾” thick AR400, where they added one plate over another rather than remove and replace them with the correct wear plate for longer life. Click Here for the full story on this chain deck.

This is particularly true when dealing with wear resistant steel. There are no industry standards for AR type steels to use as a guideline; meaning you literally are flying blind.

Here's how to do it using company data and strategic planning: After a few months allowing him to get acclimated in the position, the department team leaders held regular small group discussions and talked about their challenges and potential ideas.

These short meetings initially focused on what the production people saw as the Chronic Issues with their equipment on a daily or weekly basis.

Digging into past department purchases and logging each piece of equipment into a spreadsheet is time consuming, but necessary.

It is essential to clarify which wear plate items in their manufacturing equipment required the greatest investment of parts and labor.

Then sort the spreadsheet by the maintenance investment of each wear plate application, what was replaced and the dollar amount involved.

The purpose is to identify which of these wear resistant steel items could potentially trigger an immediate production shutdown.

These are your top priority items. Armed with this information, they had a more in depth meeting with production to determine what can be done with limited budget and labor resources.

Target Your Focus


Imagine your goal as a circular target with concentric rings. The bullseye is at the center.

The “A” Outermost Ring is where you are today, struggling to just keep things running.

The “B” Center Ring are those parts of your business you have improved, but still requires fine tuning. Here you will continue finding incremental advancements heading toward your best practices. Each movement closer to the center of the bullseye delivers improved reliability and considerably fewer breakdowns.

The “C” or Inner Ring/Bullseye of the circle represents your goal. This is where the important parts of your business are running smoothly.

Equipment operating in the bullseye has planned shut downs for upgrades and repairs at your convenience. Working in this area is your greatest efficiency.

This exercise only works if you answer the following questions honestly:
1. List three irritating or frustrating situations, and/or tasks in your business or equipment.
2. List three okay or acceptable situations, and/or tasks in your business or equipment.
3. List three intriguing and motivating situations, people, and/or tasks in your business or equipment.

Out of 100%, what percentage of your time are you CURRENTLY spending in "A", "B", and "C" activities?

More importantly, in 90 days, what percentage of your time do you WANT to spend in "A", "B", and "C" activities?

For example, you might be spending 10% of your time on "A" activities right now, and in 90 days you want to be spending 0% of your time there.

And you might be spending 40% of your time now on "C" activities, and in 90 days you want to be spending 70% of your time there.

Every 90 days you always want to be eliminating your current irritating situations and tasks, and automating and systematizing the "okay" situations, and tasks.

Eliminate the A's, and systematize and automate the B's. By doing this, you will have A LOT more time to focus on "C" (fascinating and motivating) people, situations, and tasks.

Having listed your current "A", "B" and "C" activities above, here’s what to do next:

1. List the three actions you're going to take over the next 90 days to eliminate each of the three irritating situations, and/or tasks you listed.

2. List the three actions you're going to take over the next 90 days to systematize and automate the three "okay" activities you listed.

3. List the three actions you're going to take over the next 90 days to expand the three fascinating and motivating, situations, and/or tasks you listed.

Finally, answer this question: What's the ONE "Game Changer" you're going to focus on over the next 90 days?

A game changer is an action which would change the outcome of the game for your business.

Of course, you can have more than one game changer...but over the next 90 days, what's the ONE ITEM you're going to focus on?

For over the last 40 years JADCO has focused exclusively on delivering consistent, longer equipment life for our customers.

Now you understand why we are able to deliver better results to our customers. We think differently by strictly focusing to improve your current results.

Allow us to help you today by calling (724) 452-5252, or email

We will schedule a meeting with one of our local wear plate specialists at a time that best fits your schedule.

Remember, the only thing you have to lose by not working with JADCO, are your profits.

When your standard AR wear plate gives out, give JADCO a shout! (724) 452-5252