COURSE OUTLINE

World class performance can only be achieved with a reliability strategy that includes operations, maintenance, engineering, human resources and procurement, fostering a reliability culture in the company. The course is highly practical and includes the latest ideas required to gain maximum economic value from the program. An overview of management concepts is presented together with a reliability roadmap, followed by more in-depth discussions on the technical elements required for reliability improvement. Short workshops are held to discuss core elements such as reliability audit, criticality analysis and RCA.

 

OUTCOMES

By the end of the course, participants will be able to:

• Calculate the economic value added (EVA) delivered through reliability improvement

• Analyze current performance against best-in-class benchmarks

• Develop a reliability strategy that aligns with the unique needs of the business

• Develop pro-active and re-active initiatives to improve reliability

• Engage colleagues to develop a reliability culture.

 

 

TARGET AUDIENCE

This course will benefit reliability engineers, maintenance managers, maintenance supervisors, planners, project engineers, operations managers, shift managers and operations supervisors.

 

RELIABILITY IMPROVEMENT

 

A. MANAGEMENT ELEMENTS

1. Asset Management

• Asset management kernel

• ISO 55000 outline

• The Global AM Forum & AM Societies

• ISO 55000 - ¶10 Continual Improvement

  • Video - AM Journey

 

2. Reliability Definition

• Introduction to Reliability

• Enterprise Reliability

• Reliability 4.0

  • Video - Twin Technology

 

3. Reliability Improvement Management

• The Costs of Un-Reliability (COUR)

• Reliability Roadmap

• Reliability Management

• Reliability Culture Change

  • Video - Reliability Excellence

  • Workshop - Reliability Audit

  • Workshop - Financial Calculations

  • Workshop - Pareto Analysis

 

B. TECHNICAL ELEMENTS (PRO-ACTIVE)

1. Equipment Hierarchy

2. Asset Criticality

3. Maintenance Content Optimisation

• Plant Maintenance Optimisation (PMO)

• Reliability Centered Maintenance (RCM)

4. Workflow Management

• Planning & Scheduling

• Procedure Optimisation

• Training

5. Condition Monitoring

• Technologies

• Vibration monitoring

• Oil analysis

• Thermography

• Ultrasound

• Electric motor testing

• Transformer testing

• Implementation

  • Video - Wireless vibe monitoring

 

6. Proactive Maintenance Elements

• Pro-Active Maintenance Definition

• 5S Work methodology

• Autonomous Maintenance (Operator Driven Reliability)

• Precision Maintenance (mechanical & electrical)

• Lubrication

• Contamination control

  • Video – Autonomous Maintenance

 

C. TECHNICAL ELEMENTS (RE-ACTIVE)

7. FRACAS

8. RCA

• RCFA Introduction

• RCFA Terminology

• RCFA Techniques

• 5 Why

• Fishbone

• Fault tree

• Cause Mapping

  • Video – Fishbone

  • Video - Five-Why

• Physical Failure Elements

• Human Failure Elements

• Latent Failure Elements

• 5-Why as Basis to Cause Mapping

• Expanding the investigation

• Blame vs. Prevention

• RCFA vs. FMEA

• Risk mitigation

• RCFA incident/failure recording

• RCFA, risk and reliability relationship

• RCFA scale

• RCFA teams, facilitation & reporting Workshop – RCM

  • Workshop – Criticality

  • Workshop – RCA

 

9. Defect Elimination

10. Reliability Assurance

 

PROGRAM SCHEDULE

09:00 am – 10:05 am (Duration 1 hr 5 min)

10 Minutes Break

10:15 am – 11:20 am (Duration 1 hr 5 min)

10 Minutes Break

11:30 am – 12:45 pm (Duration 1 Hr 15 min)

45 Minutes Lunch & Prayer Break

01:30 pm – 02:35 pm (Duration 1 Hr 5 Min)

10 Minutes Break

02:45 pm – 04:00 pm (Duration 1 hr 15 min)

 

 

FEEDBACK SESSION

 

What is it that the attendees have learned from the course and would wish to implement in their work place.