Overview:

The reliability engineer (RE) sees all aspects of proper plant function, puts equipment first, and makes decisions based on how machines function and their impact on production. Just as a business adviser must balance policy and diplomacy, the RE must be dedicated to preserving asset reliability and managing risk. In this five-day course, you will learn what it means to be a reliability engineer, how to build and sustain a strategic reliability engineering program, and how to gain support from other departments to achieve your facility’s reliability goals.

What You Will Learn:

• Examine the Reliability Engineer role
• Define the essential components of a successful reliability program
• Investigate reliability tools and problem-solving methods
• Practice different problem-solving techniques
• Employ reliability economics, statistics and probabilities for decision making
• Use different reliability models to analyze data for reliability
• Discuss ways to optimize your reliability program
• Cite elements of designing for reliability
• Discuss PM optimization
• Discuss 5 PdM technologies and their application

Course Content

• Introductions and Objectives
• Reliability Excellence
• RE and Interdepartmental Partnerships
• Risk-based Asset Management Strategy Introduction
• Origins of Reliability Engineering
• Reliability Terms
• RE Roles and Responsibilities
• Fundamentals of Risk Management
• Design Principals
• Purchase, Installation and Maintenance Considerations
• Reliability Modeling for Decision Making
• Reliability Program:
  • Life Cycle Asset Management - Reliability Components
  • Management of Change Process: from Identify to Audit Mitigation Actions
  • Reliability Centered Maintenance (RCM) Introduction
    • Information Gathering
    • Failure Modes, FMEA, RCM Logic Tree
    • Three-step RCM Process
    • Action Plans
     
  • Total Productive Manufacturing (TPM)
    • Five Elements of TPM
    • 12 Steps for a TPM Program
     
  • Reliability Metrics (MTBF, MTTR, Availability, etc.)
   
• RE Economics
  • Why Economics?
  • Case Flow, Time Valuke of Money, Net Present Value, etc.
  • Life Cycle Cost Analysis
  • ROI, Payback, Benefit-cost Ratio, Discounted Benefit-cost Ratio
  • Net Return, Discounted Net Return, Total Cost of Reliability, Optimum Reliability Cost
   
• Statistics
  • Uses of Statistics
  • Pareto Analysis
  • Basic Statistical Concepts
    • Normal, Exponential, Weibull
• Applying Statistics in Real-life Scenarios
• Root Cause Analysis Exercies
• Failure Reporting and Criticality Analysis System
• PM Optimization Exercise
• PdM Technologies
• PdM Technologies Scenario Exercise
• Parking Lot Discussions
• Action Plan Report-out
• Review and Celebration