Length: 2 Days
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Automotive Systems Reliability Engineering Training by Tonex

Automotive Reliability Engineering Training is a combination of theoretical lectures and practical insight that helps you gain in-depth knowledge about reliability disciplines applied to vehicle manufacturers.

An effective reliability engineering program recognizes that achievement of operational reliability is a design parameter. Decisions made during the design process influence all subsequent phases of a system’s life cycle in the form of part quality, producibility and maintainability.

Therefore, deliberate and positive measures must be instituted during the design and development process which enhance inherent reliability and minimize the introduction of latent defects during manufacturing and inspection, and degradation during field use. Applied Reliability Engineering will help participants to enhance their knowledge, deepen their understanding, and improve their skills to develop reliability improvement.

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), FMEA, RDB, FMECA, FTA, root cause analysis, problem solving (8D).

During the applied reliability engineering training course, attendees 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.

Learning Objectives 

Upon the completion of applied reliability engineering, the attendees will:

  • Learn the fundamental concepts of reliability engineering
  • List the various reliability benefits applied to process, design, products and systems
  • Discuss differences and similarities between failure rate, reliability, availability and unavailability
  • Discuss reliability of a repairable vs. A non-repairable system
  • Discuss different reliability predictions models including electrical and mechanical components, subsystems and systems
  • Describe FMEA, FMECA, Process FMEA, Design FMEA, FTA, RDB, Markov, and Event Tree Analysis (ETA)
  • 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 teamwork
  • 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

Course Outline:

Basic Reliability Engineering Concepts for Automotive Systems

  • Reliability definitions and concepts
  • Maintainability, availability. planned downtime, failure and failure rate
  • Reliability analysis
  • Reliability predictions
  • Predict the failure rate of components
  • Overall system reliability
  • Evaluating design feasibility
  • Comparing design alternatives
  • Tools to identify potential failure areas
  • Trade-off system design factors
  • Principals behind failure Rates
  • Reliability predictions and failure rates
  • Failure rate calculations
  • Component data
  • Temperature, environment, and stress
  • Basic measure of reliability
  • Mean Time Between Failures (MTBF)
  • MTBF for both repairable and non-repairable
  • Mean Time to Failure (MTTF)
  • MTTF for non-repairable systems
  • Mean Time to Repair (MTTR)

Reliability Engineering Applied

  • Role of reliability engineers and engineering processes
  • Reliability engineering activities
  • What is maintenance prevention?
  • Proactive maintenance
  • FPA, RCFA, new and rebuilt equipment
  • Analytical techniques for improvement
  • Elements of a reliability improvement system
  • Introduction to probability and statistics
  • Risk analysis
  • Design for Reliability (DFR)
  • Weibull and life data analysis
  • Reliability and maintainability analysis for repairable systems
  • FMEA and FMECA
  • Failure Reporting, Analysis and Corrective Action Systems (FRACAS)
  • Reliability Centered Maintenance (RCM)
  • Reliability Block Diagram (RBD)
  • Fault Tree Analysis (FTA)
  • Event Tree Analysis (ETA)
  • System reliability and maintainability analysis
  • Simulation modeling for reliability
  • Design for Reliability (DFR)
  • Root-Cause Failure Analysis (RCFA)

Reliability Management

  • System effectiveness
  • Availability, reliability, maintainability, and capability
  • Management systems for reliability
  • Bathtub curves for modes of failure
  • Systems reliability
  • Reliability tools
  • Reliability for mechanical components
  • Electronic system reliability
  • Software reliability
  • Reliability testing
  • Reliability management
  • Reliability policies and specifications
  • Reliability audits
  • Decision trees for reliability and system costs
  • Critical items
  • Reliability testing strategies

Reliability Modeling and Predictions

  • Principles behind reliability modeling and predictions
  • Reliability modeling
  • Reliability testing
  • Reliability predictions
  • MIL-HDBK-217 (Electronic)
  • Telcordia (Electronic)
  • NSWC (Mechanical)
  • IEC 62380 – RDF 2000 (Electronic)
  • China 299B (Electronic)
  • Failure Mode Effects and Criticality Analysis (FMECA)
  • Reliability Block Diagram (RBD)
  • Fault Tree Analysis (FTA)
  • Event Tree Analysis (ETA)
  • Binary Decision Diagram (BDD)
  • Markov Analysis (MKV)
  • MIL-HDBK-472 (MTTR)
  • Spares Scaling and Ranging (opt cost/Repstock)
  • Asset Management, Dependability, Profitability, and Safety

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

Automotive Condition Monitoring Techniques

  • Powertrain
  • Braking
  • Steering
  • Electrical system
  • Mechanical system
  • Model Validation of Dynamic Systems
  • Fuel System
  • Implementing Failure Mode Avoidance
  • Simulation and Design of Complex Vehicle Structures
  • Model-Based Optimization of a Hydraulic Backhoe
  • Design for Reliability
  • Robustness Optimization of a Vehicle Suspension
  • System Reliability Allocation based on FMEA Criticality
  • Design Optimization
  • Reliability Estimation of Large-Scale Dynamic Systems
  • Vibration
  • Thermography
  • Maintenance Excellence

Implementation of Improvements Workshop

  • 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?
  • Reliability achievement as a management discipline
  • Applied throughout the system development/production cycle
  • Life Cycle Costing & Reliability Modeling
  • Life Cycle Cost and Reliability Modeling
  • Main concepts and tools
  • Applications of these concepts and tools
  • What to avoid when considering cutting maintenance resources?
  • How to accomplish continual improvement?
  • How to engage personnel in real cost effective activities?
  • Using Tools: DFMEA, FMECA, FTA, RDB, DVP&R, 8D

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