Course Details
Your Growth, Our Mission
Course Description
This course is for operations and maintenance managers, engineers, and supervisors who want practical solutions and techniques to lift the efficiency, productivity and output of their production and operating assets. The candidates will learn useful, effective methods and tools to boost equipment reliability, lift plant availability, and get higher production output. The reliability concepts and math involved are covered in a simple, clear way that allows you to appreciate the basic ideas and apply the techniques without getting bogged down in theory. The focus will be on using practical reliability engineering methods to employ every day that improves your operating and production performance through lower maintenance costs, less downtime, fewer plant and equipment failures and higher throughput. If you want a highly effective maintenance program you use reliability engineering to understand the cause and effect relationships of equipment and operational problems. Where the consequence of failure is important you need to put into place the right actions to prevent the failure. These include introducing defect eliminating practices, timely overhauls of parts suffering usage-based failures, replacement of equipment when key parts approach end-of-life, and equipment redesign to remove failure modes. This reliability training helps you make effective and good decisions for each of those choices. With it you’ll optimize your maintenance interventions and apply sound maintenance strategy 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.
The Training Course Will Highlight ?
Training Objective
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
Target Audience
- Maintenance managers
- Reliability engineers
- Mechanical Engineer
- Operation Engineer
- Planning Engineer
- Mecahnical Techinician
- Safety engineers
Training Methods
This interactive Training will be highly interactive, with opportunities to advance your opinions and ideas and will include:
- Lectures
- Workshop & Work Presentation
- Case Studies and Practical Exercise
- Videos and General Discussions
- pre and post assessments
Daily Agenda
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
Accreditation
BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.
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