This course teaches the principles of improving asset management and maintenance decision using fundamental principles of Reliability Engineering. Attending this course will broaden ones technical ability to tackle asset reliability in a more effective manner using the many tools learned. The purpose of this course is to provide an introductory body of information that will give the engineer, engineering manager, or corporate manager the resources to start the process of organizing a reliability department within the company.

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

• Understand elements of reliability program plans and other documents that are necessary to support customer requirements
• Understand the Design for Reliability (DfR) and the tools used
• Use the design tools necessary to ensure a reliable product including prediction, allocation, and FMEA
• The student will gain an appreciation of the importance of reliability to system and product success
• How to apply reliability statistics to improve asset management
• What is the Life Cycle Cost philosophy
• The simple 5 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
• Basics in the usage of Monte Carlo simulation in RCM and Availability analyses
• Components of Human Factors Engineering in reliability
• The important terms and definitions in reliability statistics
• How to apply basic statistics in the maintenance environment
• How to calculate Net Present Value (NPV)
• The importance of RCM, RCM terminology
• Evaluating failure consequences

This CDGA training course is suitable for a wide range of professionals but will greatly benefit:

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

The expert will suggest ideas and theories to the delegates and then encourage them to test out the ideas by the use of:
• Discussion
• exercises
• Case studies & DVDs
• group exercisess
• examples

Day1

• Reliability Engineering Fundamentals

• Basic Principles of Reliability Analysis
• Definitions and classifications of equipment failures.
• Overview of failure modes and mechanisms.
• Common Causes of Equipment Failures
• Role of the Reliability Engineer

• Making Reliability Improvement Normal Practice

• Define  reliability objectives
• Develop reliability plan
• Implement reliability plan
• Monitor and measure reliability results

Day 2

• Failure Modes and Effects and Consequence Analysis (FMECA)

• Failure Modes and Effects Analysis (FMEA)
• Failure mode distributions
• Reliability Growth Cause Analysis
• Using FMEA to predict and mitigate potential failures.
• Implementing FMEA in continuous improvement processes

• Root Cause and Analysis Process

• Introduction to RCA methodologies and tools.
• Conducting RCA to determine underlying causes of failures.
• FRACAS Failure Reporting Analysis and Corrective Action System in the process
• Work Identification and Defect Reporting
• Ask 5 Whys to anaylsis faluires and action
• Case study in conducting root cause analysis and FMEA.
• Process FMEA, Design FMEA, Maintenance FMEA

Day 3

• Human Factors and Human Error

• Task Hazop
• Task Hazop Prompt words
• Credible Error
• Identify Potential Consequences
• Human Factor Engineering

• Reliability tools and techniques

• FMECA & Risk Priority Number (RPN)
• Weibull parameters, Weibull Analysis, RCM with Monte Carlo Simulation
• Pareto Charts focus effort
• Failure Data Introduction, Failure Data Analysis
• Pareto Charts, Timelines, and failure modes
• Reliability Block Diagrams (RBD)
• Fault Tree Analysis Introduction
• Event Trees and Fault Trees, Failure Reporting Systems

Day 4

•  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.
• Optimising Predictive Maintenance (Condition Monitoring)
• Repair-Replace decisions

• 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

Day 5

• Cost Benefit Analysis

• Maintenance Cost
• Cost vs. Risk Ratio Calculations
• Example of Maintenance Cost

• 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

• Inspection and Monitoring Practices

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

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