Reliability Excellence Fundamentals

A comprehensive introduction to the reliability engineering techniques most commonly applied in asset-owning organizations. Designed for those new to reliability engineering, as well as practicing reliability engineers without formal training.

Day 1 — Introduction to Reliability Improvement

• Planned Maintenance Optimization

• Maintenance quality, repair/replace decisions

• Suppliers and reliability — spare parts optimization and specifications

• Measurement — continuous improvement, performance monitoring

• Asset Management — risk-based decision making, life cycle costing

Days 2 & 3 — Reliability Centered Maintenance and PM Optimization Introduction to Equipment Strategy Development

• Benefits of improved maintenance strategies

• Origins of FMEA, RCM and PMO

• Underlying principles and process steps

Step 1 — Determine Scope of Analysis

Step 2 — Identify Functions and Functional Failures

Step 3 — Identify Failure Modes and Effects

Step 4 — Assess Consequences

Step 5 — Select Maintenance Tasks

Step 6 — Determine Task Frequencies

Step 7 — Address Maintenance Errors

Step 8 — Consolidate Schedules — windows of opportunity, sequencing, leveling workloads

Step 9 — Gain Approval

Step 10 — Implement Recommended Actions

Step 11 — Track Success Beyond Equipment Strategy

Development Days 4 & 5 — Root Cause Analysis (12-Step RCA Process)

Step 1 — Define the Problem

Step 2 — Preserve and Collect Data (treat the scene as a crime scene)

Step 3 — Minimize Further Consequences

Step 4 — Arrange the Analysis Team

Step 5 — Analyze the Data — cause-effect principles

Step 6 — Identify Root Causes

Step 7 — Develop Recommendations

Step 8 — Communicate Results — written and verbal presentation

Step 9 — Implement Outcomes — getting proactive work done in a reactive environment

Step 10 — Track for Results

Step 11 — Institutionalize the Process — senior support, policies, procedures, resources

Course Summary — Fix it once, fix it forever

Reliability Engineers, Maintenance Engineers, Mechanical Engineers, Electrical Engineers, Instrumentation & Control (I&C) Engineers, Rotating Equipment Engineers, Plant Engineers, Asset Integrity Engineers