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Advanced Reliability Engineering Masterclass

Duration: 2 Days  | 9 am – 4 pm
Wednesday- Thursday

19th – 20th May 2021

Live Stream + Online Training

UAE time / GMT +4

Brief Course Overview:

This course reviews the key concepts in Maintenance and Reliability with Condition Based Maintenance and RCFA as core to the Reliability Improvement Program. Machine fault findings originating from Condition Monitoring programs are used to display equipment health; identify risk; to action corrective work; initiate Root Cause Analysis; to identify and correct recurring failure modes … which are the cornerstone to a successful Reliability Improvement Program. It is further supported by strategies such as Pro-Active, Precision, and Operator Driven Reliability (ODR) with a specific focus on the role that people and processes play in the maintenance and operational processes; particularly how this impacts production throughput, production costs, production quality, safety, and environment.

Learning outcomes from this course

  • How to develop the best maintenance plans for each asset, (focusing first on the most critical items); applying fundamental and advanced practices to improve reliability and to implement feedback systems as part of reliability assurance
  • Understand top ten contributors to Reliability
  • The important influence of processes and peoples on the organization
  • Importance of the Defect Elimination (RCFA based) process
  • Importance of Proactive and Reactive initiatives to Improve Reliability
  • Importance of the feedback loop to the maintenance tactics
  • How to develop and apply prevention instead of a blame culture during RCA investigations
  • Use the impact on company goals to scale RCFA investigations with related improvement actions
  • Identify solutions from the cause map that will avoid recurrence of failures
  • Establish a failure recording, analysis, and corrective action infrastructure within the organization.

Testimonials (from Corsol’s RE training by Riaan Breedt)

  • “The Course was very good, would love to attend future courses of Mr. Riaan”. Director Technical – Aspin Pharmaceuticals
  • “Course was great, informative & organizers were great to have”. Executive HVAC & Utilities – Aspin Pharmaceuticals
  • “Wonderful Trainer with complete command on his subject”. Engineering Manager – ICI Pakistan
  • “Course was very informative & Knowledgeable”. Manager Planning – DG Cement Company
  • “Gather great knowledge through this course”. Sr Manager Mechanical – DG Cement Company

 

Day 1

The Reliability Improvement Process Overview

Session One (A): Asset Management

  • Asset management kernel
  • ISO 55000 outline
  • The Global AM Forum & AM Societies
  • ISO 55k continual improvement directive

Session One (B): Reliability Introduction

  • Introduction to Reliability
  • Enterprise Reliability
  • Reliability 4.0

Session One (C): Reliability – Management, Assurance & Improvement

  • The Reliability and Continuous Improvement Kernel – Asset Hierarchy / Prioritization / Maintenance Content optimization / Workflow / Condition Monitoring / Precision Maintenance / Operator Driven Reliability / Defect elimination
  • The Costs of Maintenance & Un-Reliability (COUR) as Improvement driver
  • Reliability Management
  • Reliability Assurance

Workshop – Reliability & Maintenance audits

Session Two: Optimizing Maintenance

  • Equipment hierarchy
  • Criticality
  • Maintenance History & Content Optimization
  • Reliability Centered Maintenance (RCM)
  • Plant Maintenance Optimization (PMO)
  • Workflow Management
  • Procedure Optimization & Training
  • Precision maintenance (installation, alignment, balance & electrical elements)
  • Proactive maintenance (lube application & contamination control)
  • Operator Driven Reliability

 

Day 2

Proactive Interventions – Maintenance Optimization

Session One: Condition Based Maintenance

  • Condition Monitoring – Fundamental (Overview / Inspections / Vibration monitoring / Oil analysis / Thermograph / Ultrasound)
  • Condition Monitoring – Specialized (Electric motor testing / Transformer testing)
  • Condition Monitoring – Implementation

Workshops – Criticality, RCM, CM

Session Two (A): Defect Elimination

Session Two (B): Introduction to RCFA

  • RCFA Terminology
  • RCFA Techniques (5 Why/Fishbone/Fault trees/Cause Mapping)

Session Two (C): Cause Mapping as the Basis to Risk Mitigation and Reliability Improvement

  • 5-Why as Basis to Cause Mapping
  • Expanding the investigation
  • Blame vs. Prevention
  • RCFA vs. FMEA
  • Risk mitigation

Session Two (D): Important RCFA Elements

  • RCFA incident and equipment failure recording (FRACAS)
  • RCFA, risk and reliability relationship
  • RCFA scale
  • RCFA teams, facilitation & reporting

Workshop – RCFA

 FEEDBACK SESSION:

What is it that the attendees have learned from the course and would wish to implement in their workplace?

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