Reliability Engineering Series

Find out more about Reliability Engineering here.

Designed for:

This is a knowledge-building course designed for those who are responsible for establishing policies and processes within the asset management discipline.  The course provides knowledge and  skills in reliability engineering methods to allow participants to understand the direct and indirect effects of increased asset and system reliability.

You will learn:

• The important terms and definitions in reliability statistics
  
• How to apply basic statistics in the maintenance environment
  
• How to apply reliability statistics to improve asset management
  
• What is the LCC philosophy
  
• Learn the steps for performing a LCC analysis
  
• How to calculate net present value (NPV)
  
• The simple Five Why method of failure investigation
  
• Fundamentals of Event and Causal Factor Mapping for incidents and failures
  
• Fundamentals of using Logic Trees to uncover the physical, human and latent causes of failures
  
• The importance of RCM 
  
• RCM terminology 
  
• Fundamental RCM philosophies 
  
• Failure Modes and Effects analysis for RCM 
  
• Evaluating failure consequences 
  
• The difference between FMEA and FMECA
  
• How to identify mechanical, electrical and stationary failure modes using condition monitoring (PdM) technologies
  
• How to identify the Common Traps of each PdM technology
  
• Introduction of the use of Monte Carlo simulation in RCM and
• Availability analyses
  
• Components of Human Factors Engineering in reliability
  
• The use and importance of FRACAS

About the Course:

This course is designed to teach the principles of improving asset management and maintenance decision making using the fundamentals of reliability engineering principles.

  Reliability Engineering Fundamentals

1. Reliability Engineers vs. Maintenance Engineering
2. The Engineered Maintenance Strategy

  Reliability Statistics

1. Mean, Median and Mode
   
2. Standard Deviation
   
3. Linear Regression
   
4. MTBF and MTTF
   
5. Reliability Predictions
   
6. Basic System Analysis
   
7. Weibull Calculations

  Life Cycle Cost Analysis

1. LCC Philosophy and Benefits
   
2. Financial Statements
   
3. The Cost of Money
   
4. ROI & ROA
   
5. Life Cycle Cost Calculations

  Failure Modes and Effects, Criticality Analysis (FMECA)

1. Different Types of FMECAS
   
2. Functions – Primary and Secondary
   
3. Functional Failures & Hidden Failures
   
4. Failure Modes
   
5. Effects
   
6. Criticality

  Reliability Centered Maintenance (RCM)

1. Definition of RCM
   
2. Types of Maintenance
   
3. Failure Patterns
   
4. Underlying Analysis Philosophies
   
5. Foundational Changes
   
6. 7 Steps of RCM
   
7. RCM Decision Logic

  Root Cause Analysis (RCA)

1. Examples of RCA techniques improving OEE
   
2. Discuss and demonstrate Logic Trees
   
3. Discuss and demonstrate Causal Factor Mapping
   
4. Using Pareto analysis to select chronic failures to address with RCA
   
5. Selling the benefits of RCA to management

  Weibull Analysis

1. Introduction
   
2. Definition of Reliability
   
3. Weibull Shapes
   
4. Maintenance Tactics
   
5. Understanding Failure Distributions
   
6. Weibull in Complex Systems
   
7. Weibayes

  RCM with Monte Carlo Simulation

1. Exercises using RCM and Monte Carlo Simulations

  Availibility Simulation

1. Reliability Block Diagrams
   
2. Series and Parallel Systems
   
3. Management Considerations
   
4. System Complexity
   
5. Simulation Benefits

  Condition Monitoring

1. Quantifying Mechanical Asset Health
   
2. Quantifying Electrical Asset Health
   
3. Quantifying Stationary Asset Health

  Human Factors Engineering

1. Procedures Based Maintenance
   
2. Basic Job Mapping
   
3. Introduction to Work Procedures

  Reliability Centered Design (RCD)

1. Purpose of RCD
   
2. Importance of RCD
   
3. RCD Process
   
4. RCD FMEA
   
5. Ramifications of RCD

  Failure Reporting, Analysis And Corrective Action System (FRACAS)

1. Basic Elements
   
2. Failure Reporting
   
3. Roles and Responsibilities
   
4. Analysis Methods
   
5. Database Elements

Review the week's learning:

•  How to apply reliability statistics to improve asset management
•  What is the LCC philosophy
•  Learn the steps for performing a LCC analysis
•  The simple Five Why method of failure investigation
•   Fundamentals of Event and Causal Factor Mapping for incidents and failures
•   Fundamentals of using Logic Trees to uncover the physical, human and latent causes of failures
•  Fundamental RCM philosophies 
•  Failure Modes and Effects analysis for RCM 
•  The difference between FMEA and FMECA
•  How to identify mechanical, electrical and stationary failure modes using condition monitoring (PdM) technologies
•  How to identify the Common Traps of each PdM technology
•  Introduction of the use of Monte Carlo simulation in RCM and Availability analyses
•  Components of Human Factors Engineering in reliability
•  The use and importance of FRACAS