Reliability BootcampLEORON Professional Development Institute
All available course dates
Managing physical assets would enable companies to save millions of dollars on costs while gaining tens of millions of dollars on reduced opportunity costs due to much lower production losses. Modern equipment is now so complex and the consequences of failure are so serious that it is no longer possible to develop viable physical asset management strategies using traditional approaches. An array of proven analytical techniques and management processes are now available to deal systematically with the most pressing issues confronting the managers of physical assets. Many of these techniques overlap and therefore need to be applied in a coherent and efficient manner.
Improving asset reliability is the heart of Asset Management. There are variety of
reliability improvement tools that one can use to improve reliability of a plant. While some of the tools in the market overlap significantly, others are complementary. Perhaps the most advanced and effective proactive reliability improvement methods is what we call Reliability Centered Maintenance (RCM).
Among different versions of RCM, RCM3 is the leading RCM methodology used to determine the maintenance requirements of any physical asset in its operating context. It is used to decide what must be done PROACTIVELY to ensure that any physical asset, system or process will continue to do whatever its users want it to do. The RCM3 process seeks to identify a suitable failure management policy for dealing with each failure mode in the light of its consequences and technical characteristics.
On the other hand, systems fail from time to time (even if we implement the most advanced reliability programs, they still fail although at much lower rates). Some failures are sporadic and some are chronic. So, the question would be how to prevent a failure from happening again. To deal with this, we need to use Root Cause Analysis (RCA), which is an structured way of finding root causes of a problem/failure and
developing effective solutions to avoid recurrence of the failure in future. Compared to RCM, an RCA is more REACTIVE approach and also more focused on failures that have similar causes.
Today, a reliability engineer needs to be equipped with both techniques and know where to apply which. Science of reliability in nature is very connected to math and theory of probability and statistics. So, it would be vital for any reliability engineer to have a minimum understanding of these concepts. To fulfill this important requirement, in this RELIABILITY BOOTCAMP we talk about reliability and probability
functions by focusing on Weibull distribution which is the most common probability distribution in the filed of reliability engineering. We will show how based on historical failure and replacement data of an equipment, one can establish failure probability distribution of that equipment and then combined with cost of failure and cost of a preventive replacement develop optimum replacement age and interval.
Last but not the least, an organization cannot achieve reliable operation without accessing the necessary parts at the time of need. Almost all the inventory systems today (or vast majority of them) do not optimize their inventory Min-Max and policies to achieve their plant reliability requirement. In other words, there is a mismatch between reliability programs and inventory management systems even at the most leading companies in the world. In this program, we will be speaking about an advanced concept called Reliability Centered Spares where participants will learn how to optimize their inventory parameters (Min, Max, ROP) to achieve reliability requirements of their organization.
The program will consist of many in class individual and group exercises and many more real industrial cases with proven results. Participants would be provided with educational access to two software packages (OREST for PM optimization and RCS for spare parts management optimization).
Who should attend?
This highly practical and interactive course has been specifically designed for people:
→ Responsible for the maintenance function (maintenance managers, engineering
managers, supervisors and technical specialists)
→ Responsible for the assets themselves (plant managers and production/operations managers)
→ With special responsibility for safety and environmental integrity
→ Who actually maintains and operates equipment
→ Anyone wishing to secure optimum performance from any physical assets, from the viewpoint of safety, environmental integrity, output, product quality or customer service.
History of RCM
• Introduction to RCM and RCM3
• Growing maintenance expectations
• New maintenance techniques
• International Standards
• A Way Forward using RCM3
• History of RCM
• Performance standards (Multiple performance standards, quantitative performance standards, qualitative standards, absolute performance standards, variable performance standards, upper and lower limits)
• Different categories of functions Exercise
• Describing functions and performance standards
• The operating context
Failed States / Functional Failures
• Failed States
• Performance standards and failure
• Who should set the standard Failure Modes
– What is a failure mode?
– Failure modes (cause and mechanism) and the operating context.
– What failure modes should be listed? (Human error)
– How much detail? (Causation)
– Describing failure modes
– Levels of analysis
– Failure Effects
– Describing failure effects, what to record (local effect, next level higher effect, end
effect and potential worst cause effects) and what assumptions to make.
– Defining worth doing criteria for:
• Hidden failures consequences
• Safety and Environment consequences
• Operational consequences
• Non-Operational consequences
– Hidden failures exercise
– Failure consequences exercise
Risk Definition and Mitigation
Risk Management Strategies I Proactive Tasks
• Defining technical criteria (including frequencies) for:
– On-condition tasks (Review of all the predictive technologies)
– Scheduled restoration tasks
– Scheduled discard tasks
– Combination of tasks
Risk Management Strategies II
• Failure finding tasks (including frequency calculations)
• No schedule maintenance
• One-time changes (Redesign, Training and Procedures)
Implementing RCM Decisions
What RCM Achieves
Root Cause Analysis (RCA)
• Know the four steps of effective problem analysis.
• Be able to clearly define a problem: What happened? When happened? Where happened?
• Understand the cause and effect principle.
• Why there is no single reality, and how to map the best possible one?
• Role of Evidence in building a reality map
– Sensed evidences
– Inferred evidences
• Know the five steps of creating a reality chart
• Given a sample scenario, demonstrate competence in the creation of reality chart
Root Cause Analysis (RCA) (cont.)
• Be able to find effective solutions
– Solutions must be within our sphere of influence
– Solutions must satisfy our goals/constrains
– Solutions need to be prioritized
• Know how to find creative solutions through brain storming
• Know the key elements of an effective problem report
• Know how to get buy-In others
• State the key to effective interviewing
• Be able to Facilitate an RCA with a group
• How to implement solutions?
• How to track the results and progresses?
Quantitative Reliability Analysis
• What is component reliability? How to calculate probability of failure? How to estimate average life?
• What are main failure patterns for industrial equipment? What are their
• What is a Weibul distribution? How to calculate an equipment failure pattern
based on historical maintenance and failure data?
• How to calculate optimum replacement interval for an equipment based on
historical failure data?
• Defining optimum age-based preventive maintenance internal using historical data
and costs of failure vs cost of preventive maintenance
Case Studies: Fuel pump for an aircraft, Canadian Rail cases study, CAT 797 engine replacement case
• Introducing OREST, A Preventive Maintenance Optimization software package
• Reliability Centered Spares
• How spares part fail and how to calculate the risk?
• Protecting plants availability while reducing holding costs
• Predicting future demands of spare parts: cases study 1, case study 2: North American Utility
• Predicting Future Demand for Rarely Used Items
• The Concept of the Service Level: case studies
• Assessing risk: getting caught short, getting caught long, total risk approach: case study
• Conducting sensitivity analysis: sensitivity to criticality, lead time, price, carrying costs
• Managing repairable spares:
– Introducing Reliability Spares
– Management software
– Case study 1: electric motors of a conveyor system
– Case study 2: TFT pumps for an Oil and Gas company in North America
• Setting the reorder quantity
– Factors affecting reorder quantity
– Estimating carrying costs factors
– Estimating ordering costs
– What is Economic Order Quantity?
Why choose Leoron?
LEORON has worked with some of the largest companies in the World - but importantly we care about the individual. Through our Customer Happiness Team we ensure that everyone who attends a LEORON course has the support before, during and after to ensure their training needs are met.
We offer the highest level of training delivery, whether that be in our live-virtual training or in-classroom sessions, with our expert instructors guiding you through everything so that you’re left feeling assured and confident to utilize your new knowledge going forward.
LEORON Professional Development Institute
LEORON is the fastest growing global training institute in the World, having evolved over the past 11 years into a dominant training institute that offers a comprehensive set of training and development solutions to both individuals and businesses. Our locations...
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