Learn how to deliver equipment reliability improvement using every-day reliability engineering to enrich your operating and maintenance processes. This applied reliability engineering course provides you with valuable and insightful knowledge, along with practical case studies and hands-on data analysis activities you learn from. After a basic introduction to reliability engineering and equipment operational risk you see how reliability engineering is practically applied and used to achieve equipment reliability growth and optimize your maintenance management strategy.

By the end of this course delegates will be able to:

• Improve operating & maintenance methods &practices to get least life cycle cost (LCC) from your assets
• Optimize and develop reliable of plant and equipment designs to give you higher plant and equipment availability
• Identify how your equipment parts and systems fail so you can select the ideal maintenance strategies for your operation.
• Build and apply Reliability, Availability and Maintainability (RAM) processes for production improvement
• Improve reliability of equipment designs with data analysis of the historic failures affecting your equipment
• Understanding the practical methods and useful features of Reliability Engineering and how they can help you
• Know when to use reliability engineering to get the most benefit for your operation
• Learning which reliability engineering techniques to use to improve your operating equipment performance and profits
• Recognize how to use reliability professionals to deliver better operating outcomes and plant availability
• Realize where reliability engineering can deliver simple and low-cost reliability improvements to your operation

• Maintenance managers
• Reliability engineers
• Mechanical Engineer
• Operation Engineer
• Planning Engineer
• Mecahnical Techinician
• Safety engineers

 Day 1

Reliability Engineering Basics

• Fundamentals of Equipment Failure
  • Definitions and classifications of equipment failures.
  • Physics of Equipment Failure
  • Overview of failure modes and mechanisms.
  • Common Causes of Equipment Failures
  • Material fatigue, corrosion, wear, and operational overload.

• Frequency and Consequence
• Basic Phlillosphy of of Frequency
• Risk Ranking of event by Frequency and Consequence
• Frequency Analysis
• Risk Analysis and Risk Management

Day 2

• Event Trees and Fault Trees 

• Fault and event trees
• Performing a fault tree analysis

• Risk Matrix and Risk Triangle

• Risk assessment matrix in project management
• Risk matrix example
• Definition of risk tringle

• Equipment Criticality

• Identify Equipment Criticality
• Criticality Analysis in Maintenance
• Equipment Criticality Example

• Basic Reliability Math explained and  Performance Indicators

• Series/Parallel systems
• Probability and Distributions
• MTBF Mean Time Between Failure
• MTTF Mean Time To Failure
• MTTR Mean Time To Repair
• OEE Overall Equipment Effectiveness

Day 3

• Reliability Improvement

• Introduction to Weibull Analysis
• Introduction to Life Cycle Modelling
• Reliability, Availability and Maintainability (RAM)
• Reliability and Hazard Functions

• Human Factors and Human Error

• Task Hazop
• Task Hazop Prompt words
• Credible Error
• Identify Potential Consequences
• Task HAZOP example

• Component and equipment stress reduction

• Type of Stresses and control

• Root Cuase and Analysis Process
• - FRACAS Failur Reporting Analysis and Corrective Action Sytem in process
• - Work Identification and Defect Reporting
• - Ask 5 Whys to anaylsis faluires and action
• - Pareto Charts focus effort

Day 4

• Failure Modes and Effects Analysis (FMEA)
• - Using FMEA to predict and mitigate potential failures.
• - Implementing FMEA in continuous improvement processes.

• Reliability, Maintenance, Asset Management for Failure Prevention
• Preventive Maintenance (PM)

• Optimising Preventive Maintenance
• Condition-based Maintenance Intervals
• Optimizing Spares to Support the Maintenance Program

• Predictive Maintenance (PdM)
  • Overview of predictive maintenance technologies.
  • Using condition-monitoring tools for early detection of issues.
• Reliability-Centered Maintenance (RCM)
  • Principles of RCM and application in industrial settings.
  • Developing RCM plans to enhance equipment reliability.
  • Component Failure Data Modelling
  • Failure Distribution Curves

• Cost Benefit Analysis

• Maintenance Cost
• Example of Maintenaance Cost

Day 5

• Root Cause Analysis (RCA)
  • Introduction to RCA methodologies and tools.
  • Conducting RCA to determine underlying causes of failures.
  • Case study in conducting root cause analysis and FMEA.

• Inspection and Monitoring Practices

• Effective inspection techniques for critical equipment.
• Integrating monitoring systems into daily operations.
• The Importance of Backlog
• Scheduling for Efficiency

RECTUS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration