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

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

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 

Day 1

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

Day2

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 Cuase and Analysis Process

• Introduction to RCA methodologies and tools.
• Conducting RCA to determine underlying causes of failures.
• FRACAS Failur Reporting Analysis and Corrective Action Sytem in 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 Maintenaance 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

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