Reliability Engineering Training for Non-Engineers

Reliability Engineering Training for Non-Engineers

Reliability Engineering Training for Non-Engineers Course Description

Reliability engineering training for non-engineers covers the bases, principals, and techniques of reliability. We deliver this training course in a simple language that those individuals without an engineering and math background can understand, learn, and apply. Therefore, the focus of the training is more on problem solving techniques and less on statistical and math models.

Reliability engineering training helps you improve your business performance and profitability through reducing the costs of unreliability. We will teach you how to take advantage of reliability tools to identify cost issues and how to resolve those issues.

Reliability engineering training for non-engineers is mostly dedicated to practical exercises and problem solving. Participants are encouraged to bring in their own sample problem statements or can simply use the real-life case studies our instructors will provide in class. You will discuss the money issues related subjects to find economically feasible levels of reliability via reliability tools. This course is highly interactive and dynamic.

Added Value of Reliability Engineering Training

You will learn about:

• Reliability Engineering Principles
• Stages of Reliability
• Computer demonstration of probability plots
• Demonstration Project
• Reliability Models
• Reliability assessment techniques
• Computer demonstration of Monte Carlo models
• Management Systems for Reliability
• Mechanical Components and Systems
• Electronic System Reliability
• Demonstration Project Preliminary Commitment
• Software Reliability
• Reliability Testing
• Reliability Growth Monitoring
• Computer demonstration of Crow/AMSAA plots
• Reliability Management
• Demonstration Project Commitment

Audience

Reliability engineering training for non-engineers is a 3-day course designed for:

• Quality managers
• Reliability managers
• Production/design managers
• Warranty analysts
• Business owners
• Problem-solving team personnel
• Project managers

Training Objectives

Upon the completion of negotiation training for non-engineers, attendees are able to:

• Understand and discuss the fundamental principals and concepts of reliability engineering
• List reliability engineering assessment techniques and tools
• Use appropriate probability distribution to measure model times to failure
• Describe the relationship between the time to failure distribution, the reliability function, and the hazard rate
• Evaluate reliability values from test data and determine confidence limits on the results
• Apply necessary tools to ensure a reliable product
• Determine the differences between analyzing the reliability of a fixable and non-fixable systems.
• Develop and sustain a strategic reliability engineering
• Develop control strategies to reduce risks and increase asset use
• Develop predictive strategies
• Construct an effective predictive maintenance procedure
• Set a root cause analysis protocol to reduce the wasted time, increase productivity, and a culture of continuous improvement

Highlights of Learning and Hands-on Activities

• Learn how to performs and conduct reliability and safety analyses of  component parts, assemblies, subsystems, systems and System of Systems (SoS) utilizing established methods, tools and procedures to ensure systems/products designs are in conformance with your organizations’s established reliability and safety standards.
• In the reliability engineering training, attendees will conduct reliability analyses to support a real world product requirements and deliverables: failure prediction, reliability predictions, failure modes and effects analysis (FMEA), failure modes, effects & criticality analysis (FMECA) and Reliability Block Diagram (RBD). (hands-on using tools provided in the class).
• Learn how to conduct safety analyses to support program requirements and deliverables: fault tree analyses (FTA) and system safety analyses (SSA).
• Learn how to review reliability programs and proposals submitted to ensure that design, manufacturing, engineering, and quality assurances processes support established reliability and safety requirements and predictions.
• Learn how to review engineering designs and engineering changes to critique designs for reliability and safety including materials and configurations.

Course Outline

Overview of Reliability

• Reliability definition
• Importance of reliability
• Role of reliability
• Reliability terminology and definitions
• What is the motivation for improving reliability?
• Reliability is art
• Reliability Engineering Activities
  • Maintenance Prevention
  • System LCC Analysis
  • Proactive Maintenance
  • Capital Equipment Replacement
  • Economic Evaluation/Justification Analysis in R&M Investments
• Analytical techniques of reliability
• Elements of reliability improved system
• Inherent availability
• Maintenance management strategies
• Maintenance prevention

A Brief Introduction to Reliability Engineering

• What is Reliability Engineering?
• Business aspects of reliability engineering principles
• What is Life Cycle Cost analysis?
• What is a Reliability Prediction?
• Reliability Data Problems and Deficiencies
• Why do I need to do reliability prediction?
• What are the uses of reliability prediction?
• Probability of Failure
• Mean Failure Rate
• MTTF (Mean Time To Failure)
• MTBF (Mean Operating Time Between Failures)
• MTTR (Mean Time To Restoration; Mean Time To Recovery)
• MDT (Mean Down Time)
• Bath Tub Curve and the Weibull Distribution
• Principles behind FMEA (Failure Modes & Effects Analysis)
• Principles behind OA (Opportunity Analysis) and  Risk Analysis
• Principles behind RCA (Root Cause Analysis)
• What is a Reliability Block Diagram or RBD?
• What is a design FMEA?
• What is a process FMEA?
• What is a FMECA?
• What is FRACS?
• What is Maintainability analysis?

Managing Product Risk and Reliability

• Potential quality, reliability, and safety issues
• The cost of quality
• Product design and development:
• Predict and Prevent Quality Issues
• Quality Solutions
• Predictive reliability and risk methods
• product bill of materials and engineering change processes
• Reliability and Maintainability Prediction
• Safety and Risk Management
• Windchill
• FMEA (Failure Modes and Effects Analysis)
• FTA (Fault Tree Analysis)
• Preliminary Hazards Analysis (PHA)
• Criticality Analysis (CA)
• Event Tree Analysis (ETA)
• Evaluating and preventing product quality issues and failures
• Test and Field Reliability
• FRACAS
• Intake, analysis, and reporting of real-world reliability, safety, and quality metrics
• CAPA processes
• Advanced Statistical Methods
• Integrated statistical methods
• Reliability Block Diagram (RBD)
• Markov
• Weibull and Accelerated Life Testing
• Some tools used by a reliability engineer to identify and reduce risk include:

Real-World Reliability Risk Assessments Techniques

• Failure mode and effects analysis (FMEA)
• Process FEMA vs. Design FMEA
• Fault tree analysis (FTA)
• Reliability Centered Maintenance (RCM)

Reliability Engineering Tools

• Acquiring reliability data
• Reliability indices
• Decision trees
• Availability concepts, effectiveness equation and costs
• Probability plots
• Bathtub curves
• Pareto distributions and critical items lists
• Reliability block diagrams
• Failure modes effect and fault tree analysis
• Design reviews
• Vendor and parts control
• Thermal analysis (TA)
• Environmental stress screening (ESS)
• Crow/AMSAA reliability growth models
• Reliability policies
• Benchmarking reliability

Fundamental Principles of Reliability Analysis

• Non-Probabilistic Reliability Methods
• Probabilistic Reliability Methods
• Historical Frequencies
• Manufacturers’ survivorship/mortality curves
• Expert Opinion Elicitation (EOE)

Reliability Index (β) Methods

• Point Estimate Method
• Advanced Second Moment

Multi-state k-out-of-n Systems

• Relevant Concepts in Binary Reliability Theory
• Binary k-out-of-n Models
• Relevant Concepts in Multi-state Reliability Theory
• A Simple Multi- state k-out-of-n:G Model
• A Generalized Multi-state k-out-of-n:G System Model
• Properties of Generalized Multi-state k-out-of-n:G Systems
• Equivalence and Duality in Generalized Multi-state k-out-of-n Systems 15

Reliability of Systems with Multiple Failure Modes

• The series system
• The parallel system
• The parallel-series system
• The k-out-n systems
• Fault-tolerant systems
• Weighted systems with three failure modes

Reliabilities of Consecutive-k Systems

• Computation of reliability
• Invariant consecutive system
• Component importance and the component replacement problem
• The weighted-consecutive-k-out-of-n system
• Window systems
• Network systems

Multi-state System Reliability Analysis and Optimization

• Multi-state system reliability measures
• Multi-state system reliability indices evaluation based on the universal generating function
• Determination of u-function of complex multi-state system using composition operators
• Importance and sensitivity analysis of multi-state systems
• Multi-state system structure optimization problems

Combinatorial Reliability Optimization

• Combinatorial reliability optimization problems of series structure
• Combinatorial reliability optimization problems of a non-series
  structure
• Combinatorial reliability optimization problems with multiple-choice constraints

Modeling the Observed Failure Rate

• Survival in the plane
• Multiple Availability
• Modeling the mixture failure rate

Concepts of Stochastic Dependence in Reliability Analysis

• Important conditions describing positive dependence
• Positive quadrant dependent concept
• Families of bivariate distributions that are positive quadrant dependent
• Positive dependence orderings

Statistical Reliability Change-point Estimation Models

• Assumptions in reliability change-point models
• Some specific change-point models
• Maximum likelihood estimation
• Application

Concepts and Applications of Stochastic Aging in Reliability

• Basic concepts for univariate reliability classes
• Properties of the basic concepts
• Distributions with bathtub-shaped failure Rates
• Life classes characterized by the mean residual lifetime
• Some further classes of aging
• Partial ordering of life distributions
• Bivariate reliability classes
• Tests of stochastic aging

Software Reliability Models

• Static Models
• Dynamic Models: reliability growth models for testing and operational use
• Reliability growth modeling with covariates
• When to stop testing software
• Challenges and conclusions
• Basic concepts of stochastic modeling
• Black-box software reliability models
• White-box modeling
• Calibration of model
• Issues

Software Availability Theory and Its Applications

• Basic model and software availability measures
• Modified models
• Applied models

Software Reliability Management: Techniques and Applications

• Death process model for software testing management
• Estimation method of imperfect debugging probability
• Continuous state space model for large-scale software
• Development of a software reliability management tool

Warranty and Maintenance

• Product warranties: an overview
• Maintenance: an overview
• Warranty and corrective maintenance
• Warranty and preventive maintenance
• Extended warranties and service contracts
• Stochastic point processes
• Perfect maintenance
• Minimal repair
• Imperfect or worse repaid
• Complex maintenance policy
• Reliability growth

Preventive Maintenance Models

• Block replacement models
• Age replacement models
• Ordering models
• Inspection models

Maintenance and Optimum Policy

• Replacement policies
• Preventive maintenance policies
• Inspection policies

Accelerated Life Testing

• Design of accelerated life testing plans
• Accelerated life testing models
• Extensions of the proportional hazards model

Human and Medical Device Reliability

• Human and medical device reliability terms and definitions
• Human stress—performance effectiveness, human error types, and causes of human error

• Human reliability analysis methods
• Human unreliability data sources
• Medical device reliability related facts and figures
• Medical device recalls and equipment classification
• Human error in medical devices
• Tools for medical device reliability assurance
• Data sources for performing medical device reliability
• Guidelines for reliability engineers with respect to medical devices

Probabilistic Risk Assessment

• Probabilistic risk assessment methodology
• Engineering risk vs environmental risk
• Risk measures and public impact
• Transition to risk-informed regulation
• Some successful probabilistic risk assessment applications
• Comments on uncertainty
• Deterministic, probabilistic, prescriptive, performance-based

Random-Request Availability

• System description and definition
• Mathematical expression for the random-request availability
• Numerical examples
• Simulation results
• Approximation

Reliability Engineering Training for Non-Engineers