Length: 3 Days
Applied Reliability Engineering Training
The applied reliability engineering field has been evolving to be in sync with industrial and societal developments.
Applied reliability engineering has necessitated continuous advancement of technical knowledge and ability. In the current scenario of technological development, with strong digitalization and interconnection at all levels of cyber-physical systems and in all industrial sectors, applied reliability engineering is faced with new challenges but it is also exposed to new opportunities of improvement.
It is generally agreed that the value of reliability assessment lies not in the figure obtained for system reliability, but in the discovery of the ways in which reliability can be improved.
A reliability engineer’s primary job is to test current processes and note any failures. They also look for ways to cut costs while maintaining reliable products and production methods, such as adjusting materials, equipment and employees used in the production process.
It relates closely to safety engineering and to system safety in that they use common methods for their analysis and may require input from each other.
Some of the key elements that applied reliability engineering can affect include:
- Repair and maintenance costs
- Delays further up supply chain
The goal of applied reliability engineering is to carry out an assessment as to the reliability of facility equipment and identify potential areas for improvement. This includes improvement not only in equipment design but also in terms of how it is operated and how it is maintained.
Applied reliability engineering helps quantify product quality by adding the dimension of time to the quality equation.
In other words, it’s more than making sure a product can perform its intended function at the moment of purchase. Instead, it’s about making sure that the product works without major malfunctions under normal conditions for as long as possible.
Reliability engineering does not only help organizations produce more reliable products, but it also informs maintenance teams on how to maintain them to increase MTBF (mean time between failures) and asset life span.
Increasingly, managers and engineers who are responsible for manufacturing and other industrial pursuits are incorporating a reliability focus into their strategic and tactical plans and initiatives.
This trend is affecting numerous functional areas, including machine/system design and procurement, plant operations and plant maintenance.
With its origins in the aviation industry, reliability engineering, as a discipline, has historically been focused primarily on assuring product reliability. More and more, these methods are being employed to assure the production reliability of manufacturing plants and equipment – often as an enabler to lean manufacturing.
Applied Reliability Engineering Training Course by Tonex
Applied Reliability Engineering Training course covers the concepts, tools, and techniques required for implementing successful reliability engineering. Applied Reliability Engineering Training course also will discuss reliability and maintenance program management, integrated logistics support (ILS), reliability centered maintenance (RCM), FMECA, and FTA.
Applied Reliability Engineering Training is a combination of theoretical lectures and practical insight that helps you gain in-depth knowledge about reliability disciplines.
This hands-on training course provides you the tools and techniques required to resolve reliability issues. Applied Reliability Engineering Training will help you enhance your knowledge, deepen your understanding, and improve your skills to develop reliability improvement. Through this practical course, you will receive information and facts that teach you how to make more operating profit and lower your maintenance costs through resolving your equipment reliability issues. By the end of the course, you will understand how to apply reliability engineering to develop permanent reliability that transforms companies into world-class industrial operations.
During the applied reliability engineering training course, students will be exposed to the engineering basics of the major asset management, maintenance, and condition monitoring technologies, for which the applied function is discussed, and will learn how to apply them to accomplish a proper, reliable, economical, and cost-effective operation.
The training sessions include conceptual, management, and detailed technical matter. A theoretical foundation is provided for each topic, comprehendible by all participants no matter what their background or prior knowledge is. In addition, detailed technical material will be provided for each topic. It is crucial that students are familiar with a broad range of tools and techniques.
- Why your equipment fails
- What do you need to do to get effective equipment reliability?
- Introduction to the concepts of reliability engineering with examples of reliability plotting and reliability curves
- Stress in the system components and how stress can affect reliability
- Fundamentals reliability modeling
- Reliability data analysis using real-world case studies
- How to improve a business plan by justifying the expense of making important reliability improvements
- Reliability improvement
- How to make the reliability growth happen in your organization
- Simple descriptions of series and parallel systems
- Affect of series configurations on reliability
- The economic costs of poor reliability
- Business-wide costs of your breakdowns
- Identifying and calculating the operating risk
- Measuring your real operating risks and demonstrate it on a risk matrix
- Impact of poor reliability on the business
- Impact of failures and hidden defects on the future reliability of the plant and equipment
- Tools and techniques to resolve your reliability issues and enhance the reliability of your equipment
- Inhibiting errors to put quality assurance into maintenance work
- The basics of life-cycle costing
- Best preventive and predictive maintenance strategy
- Cost-benefit models
- Change management
Which Industries Can Benefit from this Training?
- Chemical and Petrochemical
- Oil & gas
- Power, Utilities and other Infrastructure
Applied reliability engineering training is a 3-day course designed for:
- Maintenance engineers and managers
- Shop-floor personnel
- Manufacturing Managers
- Plant managers
- Reliability engineers
- Condition monitoring engineers
- Project engineers
- Operations managers
- General managers
- Project managers
Upon the completion of applied reliability engineering, the attendees are able to:
- Understand the fundamental concepts of reliability engineering
- Determine the practical applications of reliability engineering
- Decide which reliability strategy is the best under certain conditions
- Explain asset health management, dependability, profitability, safety & the role of reliability engineer
- Describe reliability & equipment failure concepts
- Use maintenance & failure data and knowledge to develop a business case for improved asset management
- Understand, develop, and implement root cause Analysis & equipment postmortems
- Explain asset management excellence through inter-department team work
- Prioritize actions using criticality & risk ranking
- Apply FMECA, RCM, Reliability Modeling, & Life Cycle Costing
- Explain and apply Key Performance Indicators, benchmarking & cost benefit analysis
- Identify human factors & organizational issues
- Definition of reliability engineering
- Importance of reliability?
- Impact of reliability on the system and business
- Reliability terminology
- Why reliability is not luxury but necessary?
- Predictive and preventive techniques
- Reliability improved system features
- Maintenance management strategies
Reliability Quantification on Paper
- The bathtub curve
- Life distributions
- Distribution functions
- Particular life distributions
- Modeling system reliability
- Series systems
- Active redundancy
- M-out-of-N redundancy
- Reliability prediction
- Life cycle
- Reliability approaches
- Top-down methods
- Bottom-up methods
Reliability Engineering Gears
- Gathering data
- Reliability indices
- Decision trees
- Availability concepts, effectiveness equation and costs
- Probability plots
- Bathtub curves
- Pareto distributions and critical items lists
- Reliability block diagrams
- Design reviews
- Vendor and parts control
- Thermal analysis (TA)
- Environmental stress screening (ESS)
- Crow/AMSAA reliability growth models
- Reliability strategies
- Benchmarking reliability
Reliability Engineering in Actions
- Maintenance Prevention
- LCC Assessment
- Positive Maintenance
- Capital Equipment Replacement
- Cost/effective estimation
Asset Management, Dependability, Profitability, and Safety
- Asset management concepts
- Roles and responsibilities in achieving profitability
- Striving for continuous improvement
- How maintenance and condition monitoring fit into this picture
Reliability & Equipment Failure Concepts & Causes
- When/why equipment deterioration occurs
- Common poor maintenance practices, their impact & failure patterns
- The basics of reducing deterioration
- The real cost of poor maintenance
From Data to Business Case
- Turning data into information
- Using information to achieve wisdom
- Using wisdom to influence management and to achieve outcomes
Overview of Condition Monitoring Techniques
- Vibration theory and its impact on equipment
- Displacement, velocity, and acceleration calculations
- Vibration spectra and what they mean to maintenance
- Thermal radiation theory (emissivity & black bodies)
- Critical camera adjustments
- Diagnosis using thermal images
- What is Ultrasonics?
- Why is it important in equipment monitoring?
- Use to detect leaks, faulty steam traps, bearing & electrical problems and to monitor re-greasing
Root Cause Analysis
- How to identify failed equipment?
- Standard root cause approaches
- Setting & controlling Scope?
- Who should be involved?
- Human factors
- Reporting outcomes
- Applying Asset Management best practice
- Organizational manners
- Organizational demands for adoption of condition based maintenance
- Review of a broad range of condition monitoring applications
- The management and coordination needed for a sufficient condition monitoring program
Criticality & Risk Ranking
- Identifying potential scenarios
- Assessing the likelihood & consequences of scenarios
- Using current risk and post action risk estimates to get agreement in task priorities
FMECA – RCM – Maintenance Strategy Review
- When is “operate-to-failure” best?
- Overview of Failure Modes Effects Analysis
- Reliability Centered Maintenance and a simpler strategy review approach
- Selection of CM test interval over a component’s life
Key Performance Indicators (KPIs)
- Leading and Lagging KPI’s
- Hierarchal KPIs
- Dashboard KPI sheets
Human Factors & Organizational Issues
- What drives human/management error?
- How do we eliminate or reduce them or their impact?
Life Cycle Costing & Reliability Modeling
- Life Cycle Cost and Reliability Modeling
- Main concepts and tools
- Applications of these concepts and tools
Implementation of Improvements
- What to avoid when considering cutting maintenance resources?
- How to accomplish continual improvement?
- How to engage personnel in real cost effective activities?
Applied Reliability Engineering Training